Abstract: A flux coating device for a solar cell panel, can include a flux bath configured to receive flux and having an inlet and an outlet, in which the inlet and the outlet of the flux bath are configured to pass an interconnector below a surface of the flux, and the interconnector can include a wiring material including: a rounded portion or a circular cross-section, a core layer, and a solder layer formed on a surface of the core layer.

Abstract: Methods for repairing flange bolt holes and the resulting flange bolt holes are provided. The methods and products include the incorporation of a coating system comprising a corrosion resistant layer, which can be formed by resistance plug welding, slurry or sol-gel processing, or thermal/cold spray processing. The corrosion resistant layer can be a super alloy or ceramic material and is different than the base material of the flange bolt hole. Corrosion of the flange bolt hole can be reduced or prevented from occurring with the use of the coating system.

Abstract: A piston for an internal combustion engine is provided. The piston includes a thermal barrier coating applied to a crown formed of steel. According to one embodiment, a bond layer of a metal is applied to a combustion surface of the crown, followed by a mixed layer of metal and ceramic with a gradient structure, and then optionally a top layer of metal. The thermal barrier coating can also include a ceramic layer between the mixed layer and top layer, or as the outermost layer. The ceramic includes at least one of ceria, ceria stabilized zirconia, yttria, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray, HVOF, or wire arc spraying. The thermal barrier coating preferably has a thickness less than 200 microns and a surface roughness Ra of not greater than 3 microns.

Abstract: A system and method for authenticating an additively manufactured component is provided. The method includes locating an identifying region of the component that includes localized density variations that define a component identifier. The method further includes interrogating the identifying region of the component using a scanning device such as an x-ray computed tomography device to obtain the component identifier. The method further includes obtaining a reference identifier from a database, comparing the component identifier to the reference identifier, and determining that the component is authentic if the component identifier matches the reference identifier.

Abstract: The method for doping Mg with Ni includes cold-rolling the Mg material and then cold-spraying with Ni powder, and preferably further cold rolling the Ni-coated Mg to achieve the final Ni-doped Mg material. Preferably the Mg material is cold rolled for about 300 passes and the final Ni-doping concentration is about 5 wt. %.

Abstract: A hybrid manufacturing method may comprise depositing a secondary material onto a workpiece, finishing the secondary material to form a finished surface on the secondary material, depositing a primary material onto the finished surface, subsequent to depositing the secondary material, wherein a surface of the primary material interfaces the finished surface, and the surface of the primary material is complementary to the finished surface, and removing the secondary material.

Abstract: A method for preparing an R—Fe—B based sintered magnet, including: preparing a R1—Fe—B-M sintered magnet having a thickness of between 1 and 10 mm; spraying a layer of Tb or Dy having a thickness of between 10 and 200 ?m on each surface of the sintered magnet in a sealed box under an Ar atmosphere by hot spraying method; and transferring the sintered magnet coated with the layer of Tb or Dy to a vacuum sintering furnace, heating the sintered magnet at the temperature of between 750 and 1000° C. in a vacuum condition or under the Ar atmosphere, and allowing heavy rare earth element Tb or Dy to enter an inner part of the sintered magnet via grain boundary diffusion.

Abstract: A method for providing a metallic coat covering a surface is disclosed, which comprises: (i) applying an electrically conductive two component binder on said surface; (ii) electrostatic spraying a metal powder on the binder applied in step (i); wherein the metal powder comprises metal particles with an average diameter less than 80 micron.

Abstract: An apparatus (20, 21) and method (80) operable to: feed (82) a granulated feedstock (26) into a chamber (22); apply (84) a melting or sintering energy (28) in programmable scans (30) producing a material deposit (32) overlaid with slag (34) in the chamber (22); position (86) a slag removal device (40, 52) such that its cutting surface (35) is coincident with a top surface (33) of the material deposit; cut or break the slag free (88) from the material deposit with the slag removal device; separate (92) the removed slag from a reusable portion of the granulated feedstock in a separator (42); and feed (94) the reusable portion of the granulated feedstock to the top surface of the material deposit for repeating (96) the above operations.

Abstract: A plating apparatus and method to perform plating in non-through-hole openings or through-hole openings of a printed wiring board having at least either non-through holes or through-holes to form via-hole conductors or through-hole conductors. The plating method contacts a printed wiring board having the non-through holes or through-holes with a plating solution including plating ingredients, and plates metal on a surface of the printed wiring board while making contact with at least a portion of a pliable contact body.

Abstract: Methods of forming a blade and rendering a blade resistant to erosion includes positioning a backing plate(s) or elongated backing plate(s) adjacent at least one side of a forward face of a leading edge surface of the blade. The methods include depositing an erosion resistant material in a plurality of layers by fusion bonding the erosion resistant material to the forward face of the leading edge surface of the blade. The backing plates providing a template or guide for depositing the plurality of layers of erosion resistant material. The plurality of layers of erosion resistant material form an erosion shield and a leading edge of the blade. Methods include removing the backing plate.

Abstract: A method for fabricating a direct metal deposition (DMD) structure having substantially fully forged structural qualities is provided. In various embodiments, the method includes depositing a layer of metallic material onto an existing metallic structure having a microstructure that provides the existing metallic structure with substantially fully forged structural qualities. The DMD layer has a microstructure that provides the DMD layer with non-forged structural qualities.

Abstract: A method for making a riser tensioner component is provided. The method comprises the steps of (a) applying a cold spray composition to a metal substrate to achieve a first coating on the metal substrate, wherein the cold spray composition comprises a metal alloy, and wherein the first coating has a thickness in a range from about 5 to about 50 mils; and (b) rough finishing the first coating to achieve a second coating having an average roughness, Ra of less than about 32 micro-inches. A riser tensioner component is also provided, wherein the riser tensioner component comprises a cold spray applied coating on a metal substrate, wherein the coating comprises a metal alloy, and wherein the coating has a thickness in a range from about 5 to about 50 mils; and an average roughness, Ra of less than about 32 micro-inches.

Abstract: A protective coating is applied to a bell body composed of bronze by simply dip-coating the bell with an outer layer of zinc. The process is carried out by immersing the bell body in a hot aqueous solution containing sodium hydroxide and powdered free zinc. After the bell is removed from the coating solution it is rinsed and then polished. The coating protects the bell from environmental contaminants without changing the frequency or musical quality of the bell and therefore may be used equally with newly manufactured or refurbished bells.

Abstract: Provided is a method of patterning a catalyst using nano imprint lithography. The method includes slurrying a catalyst, preparing a stamp for forming a catalyst pattern, forming the catalyst pattern by coating a substrate with the catalyst slurry, imprinting the stamp on the catalyst slurry and performing patterning simultaneously with calcination through nano imprint lithography, and drying the patterned catalyst. As the catalyst pattern is formed through the nano imprint lithography, a surface area of the catalyst increases and it is easy to pattern the catalyst according to the shape of the stamp.

Abstract: A method to improve corrosion, abrasion, resistance to environmental degradation and fire resistant properties of structural components for use in oil, gas, exploration, refining and petrochemical applications is provided. The structural component is suitable for use as refinery and/or petrochemical process equipment and piping, having a substrate coated with a surface-treated amorphous metal layer. The surface of the structural component is surface treated with an energy source to cause a diffusion of at least a portion of the amorphous metal layer and at least a portion of the substrate, forming a diffusion layer disposed on a substrate. The diffusion layer has a negative hardness profile with the hardness increasing from the diffusion surface in contact with the substrate to the surface away from the substrate.

Abstract: Compositions and methods for silver plating onto metal surfaces such as PWBs in electronics manufacture to produce a silver plating which is greater than 80 atomic % silver, tarnish resistant, and has good solderability.

Abstract: Perfluoroisopropyl-substituted perfluorophtalocyanines, including zinc (II), copper (II) and oxo-vanadium (IV) complexes of 29H,31H,1,4,8,11,15,18,22,25-octakis-fluoro-2,3,9,10,16,17,23,24-octakis-perfluoro(isopropyl)phthalocyanine (F64Pc), may be sublimed under high vacuum conditions. The compounds/molecules produce advantageous thin films (20-100 nm) on glass substrates by physical vapor deposition. Many potential applications of the disclosed compounds/molecules are disclosed, e.g., as semiconductor materials. In situ electrical conduction and optical transmission measurements during the deposition process reveal the formation of conducting pathways and potential microscopic intermolecular electronic couplings.

Abstract: A high-energy treated cutter comprising a substrate having a top surface, an outer region, and an inner core and a wear resistant layer coupled to the top surface. The high-energy treatment alters the substrate's physical properties so that the inner core provides greater toughness and the outer region provides greater hardness, and greater abrasion resistance. The layer is protected prior to commencement of the treatment. In one embodiment, a cover is positioned to surround the layer and then the cutter undergoes treatment, wherein the cutter is subjected to impact forces with other cutters. In another embodiment, the cutter is positioned within a recess formed in a tray table, thereby providing protection to the layer. The cutter is secured in place via vacuum, glue, or weight. A spray nozzle applies shot material directed to the substrate of the cutter, thereby applying the impact forces to alter the substrate's properties.

Abstract: A method for making a riser tensioner component is provided. The method comprises the steps of (a) applying a cold spray composition to a metal substrate to achieve a first coating on the metal substrate, wherein the cold spray composition comprises a metal alloy, and wherein the first coating has a thickness in a range from about 5 to about 50 mils; and (b) rough finishing the first coating to achieve a second coating having an average roughness, Ra of less than about 32 micro-inches. A riser tensioner component is also provided, wherein the riser tensioner component comprises a cold spray applied coating on a metal substrate, wherein the coating comprises a metal alloy, and wherein the coating has a thickness in a range from about 5 to about 50 mils; and an average roughness, Ra of less than about 32 micro-inches.

Abstract: A polymer composition containing at least one thermoplastic polymer, in particular polyamide. To reduce the formation of conductive deposits on a metal or metal-plastic composite 10 coated and/or extrusion coated using the polymer composition, the polymer composition contains at least one copper halide and at least one alkali halide.

Abstract: A method for fabricating a direct metal deposition (DMD) structure having substantially fully forged structural qualities is provided. In various embodiments, the method includes depositing a layer of metallic material onto an existing metallic structure having a microstructure that provides the existing metallic structure with substantially fully forged structural qualities. The DMD layer has a microstructure that provides the DMD layer with non-forged structural qualities.

Abstract: A method of preparing a gas separation membrane system and the gas separation membrane system itself, wherein the method includes applying a layer of a gas-selective material to a porous substrate followed by heat-treating thereof in an inert gaseous atmosphere and then polishing and repeating these steps to thereby provide the gas separation membrane system or a structure that may suitably be used in a gas separation membrane system.

Abstract: A process is provided for the protection of a metal substrate of an aircraft part, in particular made of aluminum alloy, from corrosion and abrasion. The method includes the formation, on the substrate, of a coating made of alloy of zinc and nickel and then polishing the coating thus formed. This process can additionally include applying, to the polished coating made of alloy of zinc and nickel, a transparent and airtight surface coating.

Abstract: A method involves forming a first surface on a substrate, applying to the first surface a layer of a material having a thickness less than approximately 10 microns, and precision polishing the layer of material to form a precision optical second surface on a side of the layer opposite from the substrate. A different aspect involves an apparatus that includes a substrate having a first surface, and a layer provided on the surface and having a thickness less than approximately 10 microns, the layer having on a side thereof opposite from the substrate a polished second surface with an RMS surface roughness less than approximately 10 Angstroms.

Abstract: An armor system and method involves providing a core material and a stream of atomized coating material that comprises a liquid fraction and a solid fraction. An initial layer is deposited on the core material by positioning the core material in the stream of atomized coating material wherein the solid fraction of the stream of atomized coating material is less than the liquid fraction of the stream of atomized coating material on a weight basis. An outer layer is then deposited on the initial layer by positioning the core material in the stream of atomized coating material wherein the solid fraction of the stream of atomized coating material is greater than the liquid fraction of the stream of atomized coating material on a weight basis.

Abstract: The present invention relates to a magnesium-based composite material includes at least two magnesium-based metallic layers; and at least one magnesium-based composite layer respectively sandwiched by the at least two magnesium-based metallic layers. The present invention also relates to a method for fabricating a magnesium-based composite material, the method includes the steps of: (a) providing at least two magnesium-based plates; (b) providing a plurality of nanoscale reinforcements; (c) sandwiching the nanoscale reinforcements between the at least two magnesium-based plates to form a preform; and (d) hot pressing the preform to achieve the magnesium-based composite material.

Abstract: A method of controlling edge definition of viscous material applied to an application area on a substrate comprises dispensing a row of droplets of the viscous material onto the application area with a dispensing apparatus. While moving relative to the substrate along a path proximate the row of droplets, the dispensing apparatus dispenses a fan spray pattern of the viscous material. At least some of the viscous material dispensed in the fan spray pattern impinges and mixes with the row of droplets to define an edge of the fan spray pattern.

Abstract: A coated ice skate blade includes an ice skate blade having a plurality of sides and a bottom, and a compressive coating applied to the sides of the ice skate blade. Also provided is a method of producing a coated ice skate blade including receiving an ice skate blade having a plurality of sides and an unground bottom, applying a compressive coating to the sides and the bottom of the ice skate blade, and grinding the bottom of the ice skate blade to produce a radius of hollow. Another method includes receiving an ice skate blade having a plurality of sides and a ground bottom, and applying a compressive coating to the sides and the bottom of the ice skate blade.

Abstract: The present invention provides a surface treatment method for magnesium alloy, which comprising the following steps: 1) preparation; 2) fusion and uniformly coating; 3) heat diffusion, and 4) finish; so a coating alloy is placed on a magnesium alloy substrate, and the magnesium alloy substrate is heated so that the coating alloy is uniformly melted on the magnesium alloy substrate; when heating up to a preset temperature, the coating alloy generates heat diffusion on the magnesium alloy substrate; the coating alloy finally forms a corrosion-resistant hard layer on the magnesium alloy substrate. So, this invention features simple treatment process, stable structure and environmental-friendliness in a wide range of applications.

Abstract: A high-energy treated cutter comprising a substrate having a top surface, an outer region, and an inner core and a wear resistant layer coupled to the top surface. The high-energy treatment alters the substrate's physical properties so that the inner core provides greater toughness and the outer region provides greater hardness, and greater abrasion resistance. The layer is protected prior to commencement of the treatment. In one embodiment, a cover is positioned to surround the layer and then the cutter undergoes treatment, wherein the cutter is subjected to impact forces with other cutters. In another embodiment, the cutter is positioned within a recess formed in a tray table, thereby providing protection to the layer. The cutter is secured in place via vacuum, glue, or weight. A spray nozzle applies shot material directed to the substrate of the cutter, thereby applying the impact forces to alter the substrate's properties.

Abstract: A magnetic roll for embossing, the magnetic roll incorporating a cylindrical core having a base radial dimension, the base radial dimension being less than a finished radial dimension; magnet receiving channels within the cylindrical core; a multiplicity of magnets attached within the magnet receiving channels; at least a first armature effect resisting metal band, the band adhering to the cylindrical core's first circumferential surface, the band overlying a plurality of the magnets, and the band consisting of a deposition of metal sprayed molten metal droplets; and an outer surface, the outer surface being a radially outer periphery of the at least first armature effect resisting metal band, the outer surface being ground to reside at a finished radial dimension.

Abstract: A method for coating a combustion chamber defining component is disclosed. The method includes applying a thermally conductive layer to a surface of the combustion chamber defining component, the thermally conductive layer having a thermal conductivity greater than the combustion chamber defining component.

Abstract: Coating compositions comprising perfluoroalkyl metallo and non-metallo perfluoro-phthalocyanine compounds and associated coating methods are provided by the present invention. Perfluoroalkyl metallo and non-metallo perfluoro-phthalocyanine compounds are suitable for use as functional coatings and may be optionally combined with conductive polymers. The functional properties imparted generally include one or more of chemical resistance, thermal resistance, biological and chemical non-stick surface behavior, electrochromism, variable electromagnetic field signatures, and/or non-linear optical properties.

Abstract: The present invention includes carbon nanotubes whose hollow cores are 100% filled with conductive filler. The carbon nanotubes are in uniform arrays on a conductive substrate and are well-aligned and can be densely packed. The uniformity of the carbon nanotube arrays is indicated by the uniform length and diameter of the carbon nanotubes, both which vary from nanotube to nanotube on a given array by no more than about 5%. The alignment of the carbon nanotubes is indicated by the perpendicular growth of the nanotubes from the substrates which is achieved in part by the simultaneous growth of the conductive filler within the hollow core of the nanotube and the densely packed growth of the nanotubes. The present invention provides a densely packed carbon nanotube growth where each nanotube is in contact with at least one nearest-neighbor nanotube.

Abstract: The method of protectively coating metallic uranium which comprises dipping the metallic uranium in a molten alloy comprising about 20-75% of copper and about 80-25% of tin, dipping the coated uranium promptly into molten tin, withdrawing it from the molten tin and removing excess molten metal, thereupon dipping it into a molten metal bath comprising aluminum until it is coated with this metal, then promptly withdrawing it from the bath.

Abstract: An article protected by a thermal barrier coating system is fabricated by providing an article substrate having a substrate surface, thereafter depositing a bond coat on the substrate surface, the bond coat having a bond coat surface, and thereafter processing the bond coat to flatten the bond coat surface. A thermal barrier coating is deposited overlying the bond coat surface. The thermal barrier coating is yttria-stabilized zirconia having a yttria content of from about 3 percent by weight to about 5 percent by weight of the yttria-stabilized zirconia.

Abstract: A method of producing a metal-coated steel strip includes the steps of forming a metal coating on a steel strip and conditioning the surface of the metal-coated steel strip by smoothing the surface of the strip. The method is characterised in that the conditioning step produces residual stress of no more than 100 MPa in the strip.

Abstract: A highly corrosion-resistant material and a corrosion-resistant member which are improved in corrosion resistance, adhesion, contact electrical resistance, electrical conductivity, airtightness, etc. and are suitable for use as, e.g., a metallic separator for polymer electrolyte fuel cells (PEFC); and a process for producing them. A thin noble-metal layer is formed on the desired part of the surface of a metallic base and then subjected to compression working. The coated base may further be subjected to anticorrosive treatment with a liquid phase containing a peroxide or ozone or with an active gas atmosphere.

Abstract: Described is a method of treating or coating homogeneously at least a portion of the surface of a material selected from metallic materials having a thickness of less than 100 &mgr;m and/or polymeric materials. The method of the present invention comprises exposing at least a portion of the surface of the material to an atmospheric plasma generated by an indirect plasmatron. In the method of the present invention, the surface of the material may undergo at least one of an increase in surface tension, a surface grafting, a surface cleaning and a surface sterilization.

Abstract: Disclosed is a microlens manufacturing method which comprises the step of: positioning a X-ray mask for manufacturing the microlens on an substrate on which a sensitive film is formed, and arranging a rotation axis of the substrate and a central axis of the X-ray mask; applying X-rays to the X-ray mask to expose the sensitive film while fixing the X-ray mask and rotating the substrate; developing the sensitive film to form the microlens; performing an electroplating process on the plating base to form a metal layer; and separating the metal layer from the sensitive film structure and combining the metal layer with a mold frame for injection molding the microlens and manufacturing an injection mold.

Abstract: An adhesive curable composition which comprises, as the main component, a vinyl polymer having at least one crosslinkable silyl group represented by the general formula (1). Said composition can be used as a sealing composition, a pressure sensitive adhesive composition and a coating composition.

Abstract: A surface modification method for an aluminum substrate, which comprises treating a Ni—P plated aluminum substrate with a functional water having a plus or minus oxidation-reduction potential for a predetermined period of time in a washing step after a polishing step of the Ni—P plated aluminum substrate.

Abstract: A method of producing high quality optical surfaces is disclosed. The invention allows for the production of optical surfaces with complex geometry while retaining the high quality of the optical surface. A top layer is provided on a substrate. In order to adhere the top layer to the substrate, an adhesion layer is applied first. In the preferred embodiment, the substrate is an aluminum substrate, the adhesion layer includes a layer of zinc and a layer of nickel and the top layer is gold. The substrate is generally stress free in order to provide a flat surface with no undulations. This allows a relatively thin layer of gold to be applied which then can be diamond turned in order to achieve a reflective layer.

Abstract: A zinc coating directly covers a bare ferrous base of parking meter housing parts. A non-epoxy thermosetting electrically insulating organic non-epoxy powder coating directly covers the zinc coating. The organic coating is directly applied to the zinc coating by electrostatically charging the powder and parts with opposite d.c. voltage polarities and by heating the powder so it adheres to and covers the zinc coating. Alternatively, the base is zinc, directly covered by the organic powder coating.

Abstract: A method for producing a turbine airfoil that is coated with a beta phase, high aluminum content coating, such as substantially stoichiometric NiAl, and which has a surface finish suitable for application of a ceramic topcoat. The method involves impacting the coating with preselected particles of a preselected size so that the brittle coating is not adversely affected by chipping or breakage. The impacting produces a surface finish of 120 micro-inches or better so that a ceramic thermal barrier layer can be applied over the coating. The preferred method of improving the surface finish utilizes steel balls having a diameter of about 0.033″ and a peening intensity of no greater than about 6 A.

Abstract: A filling squeegee and a scraping squeegee are provided in a printing apparatus. The filling squeegee is moved without contacting a surface of a mask in order to fill a solder paste into openings of the mask. Unnecessary solder paste on the surface of the mask is scraped by the scraping squeegee. The solder paste is prevented from being improperly filled in or scraped from the openings even if a speed of the squeegee is increased, so that the solder paste can be printed stably on circuit board.

Abstract: When bearing layers are producing by thermal coating the coating flame causes oxidation of a part of the coating material. To reduce this oxide formation and especially to lower the formation of oxide clusters in the layer a gas stream is projected next to the burner flame with an oxygen content lower than that of air. Preferably a gas with nitrogen ≧99% is used for the gas stream and as cooling gas for the burner. The method disclosed provides a bearing layer for a connecting rod eye. The large connecting rod eye is subjected to pre-spindle trimming, cracking and further spindle trimming to the coating tolerance, sandblasted and plasma coated with an aluminum bronze to produce a microporous layer. At the start of plasma spraying the plasma layer is deposited at a high temperature, which results in good adhesion of the plasma layer to the material of the connecting rod eye and low porosity of the plasma layer.

Abstract: A method of coating an inner face of a weapon barrel with a coating material includes the following steps: introducing the coating material as a component in sheet or foil form into the weapon barrel; positioning the component in the weapon barrel such that a first face of the component is oriented toward the inner face of the barrel and a second face of the component is oriented away from the inner face of the barrel; maintaining an annular clearance between the inner face of the barrel and the component; providing the second face of the component with an explosive; and detonating the explosive for hurling the coating material of the component against the inner face of the barrel for effecting a cold welding between the coating material and the inner face of the barrel.

Abstract: A process of coating a crown wall of at least one raised part of an extrusion screw which includes the following stages: a metal bead of hardness D1 is deposited on and in proximity to at least one edge of the crown part of each raised part to be coated, said bead occupying only a fraction of the width of said crown part; a second material of hardness D2 is then deposited on the rest of the uncoated crown part, said hardness D2 being significantly different from hardness D1; the deposits made in the preceding stages are ground in order to obtain the profile and the dimensions of each raised part on the screw.