Abstract: A method and apparatus for bonding solid materials together is presented. A modulated directional flow of plasma is applied at and between the bonding surfaces of members to be bonded prior to and during the application of pressure to compress the bonding surfaces together to form a direct contact or diffusion bond.

Abstract: A radio frequency generated plasma is provided to a skin surface in a controlled manner, in order to heat and selectively damage a thin superficial layer, thereby inducing a renewal process of the epidermis. The plasma is generated by providing a vacuum to the probe, and also providing an rf pulse to an electrode within the probe, thereby creating a glow discharge that includes gas ions that contact the skin and cause the skin to heat up.

Abstract: In a system based on aluminum, zirconium and nitrogen at least one layer has covalent bonds of aluminum nitride or at least one layer has bonds of the aluminum nitride and zirconium nitride type. In a process for producing such a system an electrical gas discharge is fired in a vacuum chamber such as essentially to form a noble gas-enriched plasma resulting in ionization of the metal elements. To form the nitridic layer nitrogen is continuously fed as a reactive gas into the vacuum chamber and pumped away so as to set a reactive gas partial pressure which is used for process control purposes. The use of such a system for producing a coating on a surface is also described.

Abstract: Provided are a deposited film forming method and a deposited film forming apparatus capable of reducing discharge leakage and sparks and maintaining a stable discharge even with increase in conveyance speed, increase in film-forming speed, replacement of a roll, or the like. The deposited film forming method and apparatus is configured so that, while a belt-like member is continuously conveyed in a longitudinal direction thereof, the belt-like member is passed through a film-forming chamber, one side of which is formed of the belt-like member and which is placed in a vacuum-sealable reaction vessel, a reactive gas is introduced into the film-forming chamber, the interior of the film-forming chamber is evacuated by an evacuator to be maintained at a given pressure, a high-frequency power is introduced into the film-forming chamber to induce a plasma therein, and a deposited film is formed on the belt-like member passing through the film-forming chamber.

Abstract: A method for reducing or eliminating sagging in plasma arc keyhole welds adds a fluxing agent to the weld. The fluxing agent may be titanium nitride and/or titanium carbonitride. The fluxing agent is added using physical vapor deposition or by painting a slurry onto the weld surface.

Abstract: Multiple plasma jet path sensing positions and multiple localized steering magnetic fields for each plasma jet leg in an atmospheric plasma jet control system are described for a precise control over positions of plasma jet legs as well as their directions in a vertex zone, where a hot gas stream is generated for treatment of a semiconductor device. With a plasma jet generator system in accordance with the invention precise control over the plasma jet legs enables one to virtually eliminate plasma jet path instability at the vertex region.

Abstract: An electrode for a plasma arc torch and method of fabricating the same are disclosed, wherein the electrode comprises a metallic holder defining a cavity in a forward end. An emissive element and separator assembly is positioned in the cavity. The emissive element has a layer of relatively non-emissive material on the outer surface thereof, which is preferably applied by heating the emissive element to a high temperature such that the emissive element becomes reactive, and spraying the relatively non-emissive material on the emissive element. The coated emissive element is positioned in the separator and the assembly is heated such that the relatively non-emissive material forms a strong bond between with the separator. The superior bonds between the emissive element and separator formed according to the present invention extend the life span of the electrode.

Abstract: A glass substrate having a surface which has been leveled, preferably to a flatness of 0.04-1.3 nm/cm2 of the surface, by local plasma etching is provided. A glass substrate whose surface carries microscopic peaks and valleys is leveled by measuring the height of peaks and valleys on the substrate surface, and plasma etching the substrate surface while controlling the amount of plasma etching in accordance with the height of peaks.

Abstract: A near-surface defect in a nickel-base superalloy article having a nil-ductility range is weld repaired with a low-power, directional, spatially confined heat source. During the weld repair procedure, the body of the article is maintained at room temperature. Simultaneously, the surface of the article is locally melted in the region of the near-surface defect using the heat source to form a melted region, and thereafter the melted region is allowed to solidify. The heat source produces a shallow weld pool that allows the near-surface defect to be floated to the surface in the case of an inclusion, or welded closed in the case of a surface crack or near-surface void.

Abstract: An apparatus for dissociating gases includes a plasma chamber that may be formed from a metallic material and a transformer having a magnetic core surrounding a portion of the plasma chamber and having a primary winding. The apparatus also includes one or more switching semiconductor devices that are directly coupled to a voltage supply and that have an output coupled to the primary winding of the transformer. The one or more switching semiconductor devices drive current in the primary winding that induces a potential inside the chamber that forms a plasma which completes a secondary circuit of the transformer.

Abstract: A method for reducing or eliminating sagging in plasma arc keyhole welds adds a fluxing agent to the weld. The fluxing agent may be titanium nitride and/or titanium carbonitride. The fluxing agent is added using physical vapor deposition or by painting a slurry onto the weld surface.

Abstract: A near-surface defect in a nickel-base superalloy article having a nil-ductility range is weld repaired with a low-power, directional, spatially confined heat source. During the weld repair procedure, the body of the article is maintained at room temperature. Simultaneously, the surface of the article is locally melted in the region of the near-surface defect using the heat source to form a melted region, and thereafter the melted region is allowed to solidify. The heat source produces a shallow weld pool that allows the near-surface defect to be floated to the surface in the case of an inclusion, or welded closed in the case of a surface crack or near-surface void.

Abstract: A device to place an incision into matter with a harmonious plasma cloud. A radiofrequency generator system produces pulsed or continuous electromagnetic waveform which is transmitted by an active transmitter incising electrode tip. This generated electromagnetic wave is utilized to initiate a plasma cloud with processes such as thermal ionization and a photoelectric effect which then trigger an Avalanche Effect for charged atomic particles at the surface of the active transmitter incising electrode tip. This electromagnetic wave is impedance matched, frequency matched, power matched and tuned to the plasma cloud in order to sustain and control a harmonious plasma cloud with reduced atomic particle turbulence and chaos. This harmonious plasma cloud forms a coating over the surface of the active transmitter electrode tip as well as acts to reduce the energy output needed from the power amplifier of our plasma cutting device.

Abstract: In accordance with the present invention, a method is provided for dry cleaning a processing chamber. This method comprises the step of introducing a first cleaning process gas into the processing chamber. A plasma is formed from the first cleaning process gas and maintained for a first time period. Next, repeating the step of introducing the cleaning process gas, a second cleaning process gas is introduced into the processing chamber and maintained the plasma for a second time period. As a result, the present invention is capable of removing polymer built up on the processing chamber's interior surfaces to achieve a high yield and maintaining throughput of the substrates in the plasma processing system.

Abstract: In accordance with the present invention, a directed plasma beam is employed in air to selectively remove coatings from paper products at high production rates. The shape and intensity of the beam is controlled to obtain a controlled rate of removal of the coating. The method does not require vacuum to be established and allows for the plasma to be generated from high pressure air.

Abstract: A method of producing nanocrystalline ceramic powder by creating a plasma stream in a reactor vessel, and physically converting a ceramic precursor material into ceramic particles suspended in the vessel, using the plasma stream. A metallic reactant may additionally be introduced into the vessel using the plasma stream, wherein the metallic reactant forms ceramic particles having the same composition as the ceramic particles of the physical converting step. The plasma stream is created using an electrothermal gun. The gun may use a ceramic barrel which is eroded by the plasma stream. Alternatively (or additionally), the ceramic precursor material may be injected as particulates into the plasma stream, wherein the ceramic precursor particulates are micron-sized or larger. A novel electrothermal gun design may optionally use a replaceable insert constructed of the ceramic precursor material.

Abstract: An installation and a method for oxygen arc cutting of a metal workpiece containing at least a ferrous material, in particular a structural steel workpiece, which consists in: pre-heating locally a priming zone of the metal workpiece to be cut by subjecting the priming zone to a plasma jet; then in producing a localized fusion and/or combustion of the ferrous material contained in the workpiece, using the plasma jet or a combination of the plasma jet and an oxidizing gas flow to obtain a perforation along the whole thickness of the metal workpiece; once the perforation has been obtained, in synchronously displacing, the plasma jet and the oxidizing gas flow along a cutting path to produce a predefined slit through the metal workpiece.

Abstract: A method and apparatus for treating a workpiece using capillary discharge plasma are disclosed in the present invention.

Abstract: A plasma apparatus separately measures multiple plasma jets upstream of where the plasma jets converge into a combined plasma stream. The separate plasma jets can be separately adjusted to place the separate jets in a configuration that provides the combined stream with desired properties for a plasma treatment. The system can include an injector for a neutral jet that becomes part of the combined plasma stream. With an injector, the positions of the plasma jets can be measured relative to the injector so that the plasma jets and the neutral jet are properly aligned to form a combine plasma stream having the properties desired.

Abstract: A method and apparatus for simultaneously cleaning and bonding a wire to a bonding surface is presented. In accordance with the invention, a gas is energized to form a plasma, which is then directed in a directional pressurized flow at the wire and bonding surface to form a dynamic plasma cleaning chamber bubble around the portion of the wire and bonding surface that are to be bonded together, and then the respective portions of the wire and bonding surface are bonded together within the plasma cleaning chamber bubble.

Abstract: A collection method for an at least partially ionised sample is provided in which the part of the sample to be collected is discharged using an electrical conductor and the discharge part of the sample then leaves the confines of a retaining magnetic field. The discharged part of the sample and the non-discharged part are separated as a result. The collector and collection method are particularly suitable for use with ion cyclotron resonance where different parts of the sample are provided with a higher energy level to other parts.

Abstract: An electrode for a plasma arc torch and method of fabricating the same are disclosed, and wherein the electrode comprises a copper holder defining a cavity in a forward end. An emissive element and separator assembly is positioned in the cavity, and no brazing materials are used to secure the components of the electrode. An intermetallic compound is formed between the emissive element and the separator, and a eutectic alloy is formed between the separator and metallic holder by independent heating steps. A crimping process is also disclosed for further strengthening the electrode and increasing the operational life span thereof.

Abstract: Magnetic modules and a process for manufacturing magnetic modules are provided wherein magnetic material is deposited into one or more cavities patterned into a non-magnetic substrate die to form a plurality of magnetic cores. The patterned substrate board, which may be a composite of graphite, a composite of alumina or other non-magnetic ceramic, provides a surface for winding windows, inductor air gaps, isolations, and a mounting surface for other system components.

Abstract: A plasma apparatus separately measures multiple plasma jets upstream of where the plasma jets converge into a combined plasma stream. The separate plasma jets can be separately adjusted to place the separate jets in a configuration that provides the combined stream with desired properties for a plasma treatment. The system can include an injector for a neutral jet that becomes part of the combined plasma stream. With an injector, the positions of the plasma jets can be measured relative to the injector so that the plasma jets and the neutral jet are properly aligned to form a combine plasma stream having the properties desired.

Abstract: The invention relates to a method of treating the surface of a material or of an object by means of plasma generated by an electric discharge. It also relates to a device for implementing the method. The electric discharge is stabilized by confining said plasma in the form of at least one string, and the surface treatment is performed by putting the surface in contact with the plasma string along said string.

Abstract: An electrode for a plasma arc torch and method of fabricating the same are disclosed, and wherein the electrode comprises a copper holder defining a cavity in a forward end. An emissive element and separator assembly is positioned in the cavity. The emissive element is formed from the powders of at least two materials, and the separator includes a material that is substantially similar to one of the materials forming the emissive element. The emissive element is heated and a plurality of thermal conductive paths are formed that extend from within the emissive element to the separator that improve the thermal conductivity of the electrode.

Abstract: A plasma torch for vaporizing a molten salt containing a volatile component and a refractory component injects the molten salt into a device that includes a cylindrical shaped outer member and a cylindrical shaped inner member coaxially positioned inside the outer member to surround a chamber. An induction coil positioned between the inner and outer members generates r.f. power which is initially used to vaporize the volatile component of the molten salt to create a carrier gas having an elevated temperature. The carrier gas then heats the refractory component, under an increased vapor pressure from the carrier gas. This action, in turn, breaks down the refractory component of the molten salt into fine droplets. These fine droplets are maintained in the chamber until they also vaporize. In one embodiment, the plasma torch includes a nozzle for spraying droplets of the molten salt into said chamber.

Abstract: The present invention relates to the production of ultrafine powders using a microwave plasma apparatus and chemical synthesis technique. Microwaves generated by a magnetron (1) are passed through waveguides (2) before they arrive at the head of a plasmatron (3). These high energy microwaves ionize a plasma gas, thus releasing large amounts of energy. The energy thus released is utilized to initiate and sustain chemical reactions between the desired elements being pumped in a spiral pattern into the plasmatron (3). The reaction products are quenched rapidly in a reactor column (4) into ultrafine powders.

Abstract: A system and method for preserving stored foods. The system and method utilizes an apparatus for generating ozone and other atoms and molecules resulting from the bombardment of a feed gas with electrons having, preferably, a first electrode positioned within a channel in a second electrode. The first electrode is a substantially sealed tube made of dielectric material, having at least one electron gun positioned proximate an end thereof for firing electrons into the first electrode. In electrical communication with the electron gun is a rod, maintained in a tube also made of dielectric material, which acts to maintain a constant energy level through the length of the rod and thus the length of the electrode. Within the first electrode is an inert gas which, upon the firing of the electron gun, is formed into a plasma.

Abstract: A method and apparatus for welding together two silicon workpieces (20, 22) without the formation of cracks along the weld. In a first embodiment, current (34, 36) is passed through one or both of the workpieces to heat them to between 600 and 900° C. Then an electric, laser, or plasma welder (38, 40) passes along the seam (24) between the workpieces to weld them together. In a second embodiment, current (34) is passed through a plate (60), preferably formed of silicon, which either supports the workpieces or is brought into contact with at least one of them, whereby the workpieces are preheated prior to the welding operation.

Abstract: A cutting edge is formed by build-up welding on a die of a die assembly made of a base material of an aluminum/copper-based zinc alloy. The cutting edge comprises an underlying layer and an overlying layer. The underlying layer is made of a copper alloy that can be welded to both a zinc alloy and a nickel alloy, and the overlying layer is made of a nickel alloy. The cutting edge is of high machinability, high durability, and high hardness.

Abstract: The invention concerns a device for high frequency treatment of a liquid, solid or gaseous product comprising at least one treatment inductance (2) enclosing a tubular conduit (1) designed to be passed through by a stream of the product to be treated, said inductance (2) being powered by a high-frequency generator (3) via coupling means (22, 24).

Abstract: An automated hardfacing system useful for hardfacing roller cones is disclosed. The automated system includes a robot with an arm, a positioner, and a controller which co-ordinates the alignment of the robot and the positioner. The robot holds a hardfacing torch and is capable of movement in three axes of movement. These axes are the x, y, and z axes of the Cartesian co-ordinate system. The positioner holds a roller cone and is capable of movement in at least two axes of movement. The movement includes tilting and rotation about a Cartesian axis. The hardfacing coating produced by the automated system has improved quality and consistency as compared to the one obtained by a manual process.

Abstract: An apparatus and method which uses a plasma having a density gradient in order to accelerate ions, thereby producing a flow of energetic ions and neutral parties. The plasma gradient is produced by applying a non-uniform magnetic field to the plasma and/or providing non-uniform RF power to the plasma. Since the voltage within a plasma (i.e. the plasma potential) is dependent upon the density of the plasma, the plasma gradient produces an electric field within the plasma, which can be used to accelerate ions e.g., toward a substrate. This technique produces accelerated particles of lower energy than conventional systems, thereby causing less damage to a work piece being processed. In addition, since the ions accelerated by the apparatus have lower speeds than those accelerated by conventional systems, a larger proportion of the ions having time to recombine with free electrons before striking the work piece being processed.

Abstract: An improved toroidal low-field plasma source allows plasma ignition within a wider range of gas conditions than permitted by prior art plasma sources. Power efficiency of the plasma source is improved by automatically adjusting the power delivered to the plasma based on the load to the power supply. The plasma source can be operated over a wider pressure range than allowed by prior art plasma sources. The plasma source can be operated so as to increase the output of atomic species from the source. The plasma source can be operated to increase the etch rate of organic materials. The plasma source can efficiently remove hazardous gas compounds from effluent gas streams by converting them into scrubbable products.

Abstract: A method and apparatus for welding together two silicon workpieces (20, 22) without the formation of cracks along the weld. In a first embodiment, current (34, 36) is passed through one or both of the workpieces to heat them to between 600 and 900° C. Then an electric, laser, or plasma welder (38, 40) passes along the seam (24) between the workpieces to weld them together. In a second embodiment, current (34) is passed through a plate (60), preferably formed of silicon, which either supports the workpieces or is brought into contact with at least one of them, whereby the workpieces are preheated prior to the welding operation.

Abstract: A method for closing and/or joining a connecting joint or joining seam between two pieces of galvanized sheet metal, in which zinc or a zinc alloy whose melting point is similar to that of zinc is heated to melting temperature and is continuously introduced into the connecting joint, with the heating being performed by a plasma jet without reaching the melting temperature of the steel sheet. The use of a plasma jet allows processing zinc or a zinc alloy without producing any disturbing zinc spatter. The zinc can be supplied as a wire, powder or granulate, whereby it is introduced under an inert-gas bell. This method can also be employed for post-galvanizing weld seams, with a second plasma jet welding set following a first one, it being mechanically coupled with the same and performing the galvanizing of the weld seam by the supply of zinc in wire form without melting the steel sheet anew. Tin foils are used in a special embodiment which are applied in the joining zone of a flanged edge.

Abstract: A method of producing nanocrystalline ceramic powder by creating a plasma stream in a reactor vessel, and physically converting a ceramic precursor material into ceramic particles suspended in the vessel, using the plasma stream. A metallic reactant may additionally be introduced into the vessel using the plasma stream, wherein the metallic reactant forms ceramic particles having the same composition as the ceramic particles of the physical converting step. The plasma stream is created using an electrothermal gun. The gun may use a ceramic barrel which is eroded by the plasma stream. Alternatively (or additionally), the ceramic precursor material may be injected as particulates into the plasma stream, wherein the ceramic precursor particulates are micron-sized or larger. A novel electrothermal gun design may optionally use a replaceable insert constructed of the ceramic precursor material.

Abstract: Method of thermally depositing metal at increased rates onto a target surface, comprising: establishing and operating a high velocity plasma transferred wire arc between a cathode and the free-end of a consumable wire electrode, the energy of such plasma and arc being sufficient to not only melt and atomize the free-end of the wire into metal particles, but also project the particles as a column onto the target surface at an enhanced deposition rate for continuous periods in excess of 50 hours; surrounding the plasma and arc with high velocity and high flow gas streams that converge beyond the intersection of the wire free-end with the plasma-arc to limit turbulence of the plasma-arc, avoid direct impingement with the wire and assist the projection of the particles to the target surface; and impinging a low velocity gas flow along the axis of the advancing wire to counteract any destabilizing fluid dynamic forces attempting to move melted particles back along the wire away from the wire free end.

Abstract: A waste treatment system is provided, including a waste melter system and an air pollution control system. Hazardous and/or radioactive waste in drums is conducted through a waste feed system into a plasma chamber where the waste is exposed to heat from a plasma torch. A part of the waste volatilizes and leaves the plasma chamber for a secondary reaction chamber, in which the waste is combusted to form a waste gas stream. The air pollution control system treats the waste gas stream through quenching, filtering and scrubbing, to produce a clean gas stream suitable for release to the atmosphere. Offgas may be recirculated through the waste treatment system as desired. The waste remaining inside the plasma chamber melts and drops onto sloped processing surfaces inside a hearth located below the plasma torch. The hearth includes ground electrodes configured for electrical contact with waste held in the hearth so that the melted waste in the hearth may be further heated by the plasma torch.

Abstract: A method of fabricating a semiconductor device includes providing a semiconductor substrate, forming an oxide layer in the substrate, and adding nitrogen atoms on top of the exposed surface of the oxide film to form a diffusion barrier.

Abstract: The invention relates to a method and device for improving the surface of a substrate. Plasma is produced by a luminous discharge, close to the substrate to be treated, using a hollow cathode and an anode assigned thereto. A reactive gas located in the area of the luminous discharge is activated, causing a change to occur on the surface of substrate to provide the desired improvement. The hollow cathode is brought to a self-cleansing temperature and maintained at said temperature, whereby the parasitic deposits caused by the reactive gas are removed and/or converted. The self-cleansing temperature is stabilized by taking into account the following factors: the heating of the hollow cathode by the luminous discharge, thermal conduction carried out by the reactive gas and radiation in the direction of a cooled anode arranged at a small distance from the hollow cathode.

Abstract: Plasma processing is carried out at pressures of about atmospheric pressure, at pressures below atmospheric pressure, or at pressures above atmospheric pressure. The plasmas are generated using a RF power source and a rectangular waveguide. The plasmas can be used for applications such as materials processing and carrying out chemical reactions.

Abstract: The invention involves a process for the oxygen cutting of slabs—using one or more oxygen cutting torches—and a device for implementing the process. The process includes the steps of hanging the slab (16) using one or more electromagnets (14) separated from the slab (16) by a non-magnetic device or medium (such as air); causing a relative motion between the cutting torches (18) and the slab (16); using a carrying device (15) acting on the slab on the same side of the slab (16) as the electromagnet (14); and activating the cutting torch (18) in order to cut the slab (16) when it is transported past the cutting torch (18).

Abstract: A plasma apparatus separately measures multiple plasma jets upstream of where the plasma jets converge into a combined plasma stream. The separate plasma jets can be separately adjusted to place the separate jets in a configuration that provides the combined stream with desired properties for a plasma treatment. The system can include an injector for a neutral jet that becomes part of the combined plasma stream. With an injector, the positions of the plasma jets can be measured relative to the injector so that the plasma jets and the neutral jet are properly aligned to form a combine plasma stream having the properties desired.

Abstract: A plasma arc torch and method for cutting a workpiece in which the torch has a primary gas flow path for receiving a primary working gas and directing it through the torch to a central exit opening of the torch for exhaustion from the torch onto the workpiece in the form of an ionized plasma. A secondary gas flow path in the torch receives a secondary gas separate from the primary working gas and directs it through the torch. The primary gas flow path is in fluid communication with the secondary gas flow path substantially upstream of the central exit opening of the torch to bleed primary working gas in the primary gas flow path into the secondary gas flow path for admixture therewith to form a secondary gas mixture to be exhausted from the torch.

Abstract: A multi-layered heat resistant metal tube is disclosed. This tube has excellent anti-coking characteristics and is suitable for use under the conditions where carbon tends to deposit and accumulate thereon due to contacting with hydrocarbons at a high temperature. The tube is made by forming weld-mounted overlaid layer of a Cr—Ni—Mo alloy by building-up welding over the inner surface and/or the outer surface of a substrate tube made of a heat resistant metal. The Cr—Ni—Mo alloy consists essentially of, by weight %, Cr: 36-49 wt %, Ni: 35-63 wt % and Mo: 0.5-5 wt %. Building-up welding is preferably carried out by PPW (Plasma Powder Welding) in which the filler metal is supplied in the form of powder.

Abstract: Process and unit for the arc working, particularly plasma cutting, of a workpiece, in which a plasma torch is supplied with an electric current and with a gas mixture containing hydrogen and nitrogen and/or argon, and a plasma jet obtained by the ionization of the gas mixture by the electric current is delivered by means of the plasma torch. The hydrogen concentration in the gas mixture containing hydrogen and nitrogen and/or argon is less than 50%. The gas mixture is obtained by adding a defined amount of hydrogen to nitrogen and/or argon, immediately before the gas mixture is introduced into said torch. The defined amount of hydrogen is defined according to the thickness of the workpiece, to the grade of the constituent material of the workpiece, to the desired work rate and/or to the intensity of the electric current.

Abstract: Powder aerosols are introduced into a gas stream in metered form and without any aggregates. To this end, according to the invention, a powder is drawn, for example by mechanical device, from a reservoir area and is converted into a powder aerosol which is introduced within a flowing gas stream into a container to which ultrasound is applied. The ultrasound breaks down powder lumps and aggregates, and the aerosol can be fed in a uniform, fine powder distribution within the gas stream to a plasma burner. Apparatus for carrying out this invention includes a feed tube (4) connected to a mechanical powder feed device (6), so that an aerosol containing the powder enters a vessel (10) containing the ultrasound horn (2). The method and the associated apparatus are used for the coating of components, preferably for applying a protective coating to a turbine blade.

Abstract: An electrode for supporting an arc in a plasma arc torch. The electrode includes a metallic holder having a cavity formed in a front end portion. An insert assembly is mounted in the cavity. The insert assembly includes an emissive insert composed of a metallic material having a relatively low work function. The emissive insert has a bore formed therein for securing a non-emissive core. The core has a base portion, which provides an interface between the emissive insert and the holder. The core and base portion act to thermally conduct heat out of the emissive insert so that the service life of the emissive insert is increased by the lowering of the emissive insert's operating temperature.