Abstract: A sintered metal fiber medium as subject of the invention comprises at least a first metal fiber layer providing a first outer surface to the sintered metal fiber medium. The first metal fiber layer comprises metal fibers with an equivalent diameter D1. The medium has a mean flow pore size of less than 2 times the equivalent diameter D1. The metal fibers in the first metal fiber layer in the sintered metal fiber medium have a ratio of average fiber length L1 over diameter (L1/D1) which is preferably less than 110.

Abstract: A substrate supporting member includes: a plate-shaped ceramic body having a surface serving as a substrate supporting surface; a plate-shaped composite material body which is joined to a surface of the ceramic body opposite to the substrate supporting surface with a joint material interposed therebetween and made of porous ceramic with pores filled with metal, the composite material body having a porosity of more than 0% and not more than 5%; and a metallic plate which is joined to a surface of the composite material body opposite to the surface joined to the ceramic body with a joint material interposed therebetween.

Abstract: The invention provides a method for producing a corrosion-resistant article, where the article is conductive and subject to hydrogen uptake during electroplating of a coating. The method comprises electroplating a zinc/nickel coating on the article in an aqueous, basic plating solution containing zinc and nickel ions. The method uses an electrolyte in the form of a soluble hydroxide salt with the weight ratio of zinc ions to nickel ions in the solution being sufficient to provide the coating comprising from about 85% to about 95% by weight zinc, and about 5% to about 15% by weight nickel. The plating solution is substantially free of brightening agents which retard hydrogen bake-out.

Abstract: It is to propose an internal member for a plasma treating vessel having excellent resistances to chemical corrosion and plasma erosion under an environment containing a halogen gas and an advantageous method of producing the same, which is a member formed by covering a surface of a substrate with a multilayer composite layer consisting of a metal coating formed as an undercoat, Al2O3 film formed on the undercoat as a middle layer and Y2O3 sprayed coating formed on the middle layer as a top coat.

Abstract: A quantum interference transistor comprising an source region for emitting electron waves into a vacuum, a drain region for collecting the electron waves, a repeating nanostructure in a region between the source and drain regions for introducing a constant phase shift between a plurality of electron waves, and a gate for controlling the phase shift introduced by the nanostructure; wherein the repeating nanostructure is characterized by having sharply defined geometric patterns or indents of a dimension that creates de Broglie wave interference.

Abstract: A method is provided for depositing a hard wear resistant surface onto a porous or non-porous base material of a medical implant. The wear resistant surface of the medical implant device may be formed by a Laser Based Metal Deposition (LBMD) method such as Laser Engineered Net Shaping (LENS). The wear resistant surface may include a blend of multiple different biocompatible materials. Further, functionally graded layers of biocompatible materials may be used to form the wear resistant surface. Usage of a porous material for the base may promote bone ingrowth to allow the implant to fuse strongly with the bone of a host patient. The hard wear resistant surface provides device longevity, particularly when applied to bearing surfaces such as artificial joint bearing surfaces or a dental implant bearing surfaces. An antimicrobial material such as silver may be deposited in combination with a metal to form an antimicrobial surface deposit.

Abstract: The present invention is for a porous silicon powder comprising silicon particles wherein the outermost layers of said particles are porous. The present invention is also directed to a method of making this porous silicon powder using a stain etch method. The present invention is also directed to a method of making silicon nanoparticles from the porous silicon powders using a process of ultrasonic agitation. The present invention also includes methods of processing these silicon nanoparticles for use in a variety of applications.

Abstract: The invention concerns a method for preparing a thin ceramic material with controlled surface porosity gradient, including (A) infiltrating a porous pore-forming substrate of controlled thickness, with a ceramic material suspension; (B) evaporating the solvent; (C) a step which includes eliminating the pore-forming agents and the various organic additives, and (D) a sintering step. The invention also concerns the use of the ceramic material in the method for preparing a solid electrolyte and a mixed ionic-electronic conductor, in methods for preparing ultra-pure oxygen, for eliminating oxygen from a gaseous atmosphere, for producing heat energy, for preparing gas or liquid filtering membranes, for ceramic/metal joints, for biomaterials and sensors.

Abstract: An inexpensive mechanical fuse having a high fatigue limit ratio and high rupture reliability, and superior in forming performance, and a method of manufacturing the same are presented. The mechanical fuse is composed of Fe-based sintered alloy, and comprises an inner rim 2 fixed to one power transmission shaft, an outer rim 3 fixed to the other power transmission shaft, and plural arms 4 for linking the inner rim 2 and outer rim 3, which are formed integrally. The arms 4 include rupture portions 6 which are ruptured when exposed to an overload torque. By treating in steam, an iron oxide phase is formed in the surface layer and pore inner wall. The iron oxide phase is effective to form round pores and lower the notch sensitivity. As a result, the fatigue strength and fatigue limit ratio are enhanced.

Abstract: A bi-layer bond coating for use on metal alloy components exposed to hostile thermal and chemical environment, such as a gas turbine engine, and the method for applying such coatings. The preferred coatings include a bi-layer bond coat applied to the metal substrate using high velocity oxy-fuel (HVOF) thermal spraying. Bi-layer bond coatings in accordance with the invention consist of a dense first inner layer (such as iron, nickel or cobalt-based alloys) that provides oxidation protection to the metal substrate, and a second outer layer having controlled porosity that tends to promote roughness, mechanical compliance, and promotes adherence of the thermal barrier coating (TBC). Preferably, the outer, less dense layer of the bi-layer bond coat is formed from a mixture of metallic powder and polyester to adjust and control the porosity, but without sacrificing mechanical compliance.

Abstract: Device for manufacturing a metal foam. The device includes at least two feed pipes for introducing gas. The at least two feed pipes are arranged next to one another. Each of the at least two feed pipes project into a foamable melt. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

Abstract: A lightweight part and process and device of making the same, the lightweight part including an inner core including a metal foam. A dense core surface layer is metallically joined to the inner core. An outer wall includes an essentially pore-free cast metal layer that is at least one of positively engaged with the dense core surface layer and surrounding the inner core, and metallically joined to the dense core surface layer and surrounding the inner core. The process includes creating a core part by forming the dense core surface layer, forming the inner core of a metal foam, and metallically joining together the inner core and the dense core surface layer. The process further includes creating a finished part by positioning the core part in a casting mold, feeding a melt material into the casting mold, and allowing the melt material to solidify so as to form the outer wall.

Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.

Abstract: The invention relates to a composite material which is to be used in sliding bearings and comprises a metallic support (1) and at least one reinforcement material having an open structure (2). Said support (1) and reinforcement material (2) are connected to each other by means of a metallic connection. An overlay (4) which is a polyethylene(PE)-based layer is provided on the reinforcement material (2) as an additional layer.

Abstract: The invention concerns an alveolar structure (1) comprising at least one alveolar zone (2a, 2b) partially delimited by an associated leak tight surface (4a, 4b) . According to the invention, each alveolar zone (2a, 2b) is formed of a plurality of metallic layers (8) superimposed parallel to the associated leak tight surface (4a, 4b), each metallic layer (8) comprising a network of passages (10) opening out on either side of said metallic layer (8). The invention further concerns a method for manufacturing said alveolar structure (1) Application to fuel cells and heat exchangers.

Abstract: Disclosed is a method of forming metallic composite structures The method utilizes superplastic and quickplastic formation methodologies in conjunction with the use of appended engineered metallic foams to provide energy absorbing materials.

Abstract: Disclosed are conductive powder having a packing density of 68% by volume or more with a relative value preferably comprising 60 to 92% by weight of roughly spherical and silver-plated copper powder part of the surface of which has been coated with 3 to 30% by weight of silver based on an amount of roughly spherical copper powder with exposing at least a surface of a portion of an alloy of copper with silver, and the surface of which is coated with 0.02 to 1.0% by weight of an aliphatic acid based on an amount of the roughly spherical and silver-plated copper powder, and 8 to 40% by weight of silver powder, and a method for preparing the same.

Abstract: A contact material which provides improved wear resistance as well as reduced adhesion utilizing the features of an intermetallic compound having an ordered phase, with the intention of (i) improving the seizure resistance and/or wear resistance of an implement bearing which slides under low-speed, high-surface-pressure conditions and is susceptible to lubricant starvation; (ii) preventing abnormal noises; and (iii) achieving prolonged greasing intervals. The contact material contains 10% by volume or more a metallic alloy phase having such a composition range that causes an order-disorder transition. The metallic alloy phase is a Fe base alloy phase containing one or more elements selected from the group consisting of Al, Si, Co and Ni.

Abstract: Coating systems according to the prior art, wherein a ceramic layer is applied to a metallic layer of the coating system, the connection between metal and ceramic often being poor. A coating system (20) according to the invention has a porous layer (4) in which a ceramic (7) is at least partly disposed, so that the connection between ceramic (7) and the metal of the porous layer (4) is improved.

Abstract: The present invention provides a film-coated article coated by a film having silicon oxide as a main component, in which recesses and projections conferring super hydrophobicity or super hydrophilicity are formed. This film includes minute projections and columnar projections, and the columnar projections are formed by local growth of the minute projections in a thickness direction of the film or formed with a plurality of minute particles constituting the minute projections laminated locally.

Abstract: An improved proton exchange membrane fuel cell assembly and fuel cell stack assembly are provided for the economical and efficient production of electricity. The present invention comprises improved flow fields, which provide improved and more efficient mass transport of the reactants in the fuel cell and the fuel cell stack assembly. The improved flow fields comprise three-dimensional open-cell foamed metals that are preferably plated with gold. The improved reactant supply system comprises an improved distribution frame to house fuel cells wherein the reactants are directly connected to the improved flow fields.

Abstract: Metal-containing nanostructured films are prepared by electrodepositing a metal-containing composition within the pores of a mesoporous silica template to form a metal-containing silica nanocomposite. The nanocomposite is annealed to strengthen the deposited metal-containing composition. The silica is then removed from the nanocomposite, e.g., by dissolving the silica in an etching solution to provide a self-supporting metal-containing nanostructured film. The nanostructured films have a nanowire or nanomesh architecture depending on the pore structure of the mesoporous silica template used to prepare the films.

Abstract: A metallic porous body includes a number of protrusions formed on obverse and reverse sides of a metal sheet so as to protrude alternately with one another; each of the protrusions being formed into an truncated-shape wherein an opening portion punched out in the direction from the upper-side bottom to the lower-side bottom is formed in the upper-side bottom of each protrusion, and a vertical distance (d) between the upper-side bottom on the obverse side and the upper-side bottom on the reverse side, and a height (e) of a punched portion have a relation: 0.3<e/d<0.9, thereby attaining a metallic porous body without a burr or a edged convex portion on its outside surface, with a large number of fine pores arranged at fine pitch and a light-weight and robust skeleton.

Abstract: A porous sintered metal comprising voids at least partially communicating with each other, and pores provided in walls of the voids, the porous sintered metal having a BET surface area of 700 cm2/cm3 or more, and an average diameter of the pores being 1 ?m or more when measured by a mercury press-in method. The porous sintered metal is produced by blending a metal powder, a binder and resin particles to prepare a mixture in which the resin particles are dispersed; molding the mixture to provide a green body; selectively extracting the resin particles from the green body with a solvent; debinding the extracted green body by heating; and sintering the debound green body.

Abstract: A composite rigid foam structure that has a skin or coating on at least one of its surfaces. The skin is formed in situ by thermal spray techniques. The skin is bonded substantially throughout the surface of the porous substrate to the peripheries of the pores. The skin on the average does not penetrate the surface of the substrate by more than the depth of about 2 to 5 pores. Thus, thermal spraying the skin onto the rigid foam produces a composite that is tightly and uniformly bonded together without unduly increasing the weight of the composite structure. Both thermal conductivity and bonding are excellent.

Abstract: The invention relates to a process for the production of sintered porous bodies, to porous bodies produced correspondingly using the process, and to their use. With the solution according to the invention, sintered bodies which achieve improved properties, such as an increased surface area, deformability of the structures at room temperature or modification of the initial pore volume, are to be produced. To this end, at least one sintering-active powder which forms at least one intermetallic phase or mixed crystals is applied to the surface of a porous basic body. Heat treatment is to be carried out subsequently, in which intermetallic phases or mixed crystals which increase the specific surface area can be formed.

Abstract: Device and process for manufacturing a metal foam. The device includes at least two feed pipes for introducing gas. The at least two feed pipes are arranged next to one another. Each of the at least two feed pipes project into a foamable melt. The process includes introducing gas into a foamable molten metal from at least two neighboring similarly dimensioned feed pipes projecting into a metallurgical vessel and forming bubbles in an area of ends of the projecting pipe, whereby abutting areas of adjacent bubbles form particle-containing interstructures.

Abstract: It is to propose an internal member for a plasma treating vessel having excellent resistances to chemical corrosion and plasma erosion under an environment containing a halogen gas and an advantageous method of producing the same, which is a member formed by covering a surface of a substrate with a multilayer composite layer consisting of a metal coating formed as an undercoat, Al2O3 film formed on the undercoat as a middle layer and Y2O3 sprayed coating formed on the middle layer as a top coat.

Abstract: A composition of a porous body for use as biomaterial according to the present invention is produced by adding Al (aluminum) in the amount of 0.1 to 3.0 atomic % to a porous composition consisting of titanium, nickel, iron and molybdenum, and it promotes the growth of living tissue and cells into pores. By the addition of Al to Ni, Ti, Fe and Mo, the temperature of formation of the liquid phase is lowered, and thus the diffusion of the constitutional elements of the composition is promoted, and the uniform distribution of the constitutional elements increases. As a result, the proportion of micropores in the porous body becomes increased to the extent that the distribution of micropores having the size in the range of 10?2 ?m˜10 ?m is more than 5% in the metal bridge.

Abstract: The subject of the invention is a layer system for the decorative coating of galvanizable work pieces. In order to have a layer system which meets strict requirements with regard to corrosion resistance and which, at the same time, has a high abrasion resistance and, in addition, provides a high degree of freedom with regard to decorative coloration, the invention proposes a layer system which is formed by galvanic deposition and comprises a base coat consisting of at least one bright layer and one discontinuous chrome layer as well as a cover coat of mechanically resistant materials deposited by the PVD process.

Abstract: A bipolar plate for use with a fuel cell is provided including an electrically conductive foam as a coolant layer between thin metal foil layers. The thin metal foil layers are provided with serpentine flow field patterns on a surface thereof.

Abstract: A method of producing seamless, multi-layer, bonded, metallic laminate materials of arbitrarily long length is provided. The method includes affixing together, for example via continuous resistance welding, and sintering at least two continuous, metallic layers to form a continuous laminate strip material.

Abstract: The invention provides a hydrogen permeable structure, which can effectively prevent peeling-off of a hydrogen permeable film and hence has higher durability, and a method of manufacturing the structure. The hydrogen permeable structure has a hydrogen permeable film formed on the surface of or inside a porous support, having a thickness of not more than 2 &mgr;m, and containing palladium (Pd). The hydrogen permeable film is formed on the surface of or inside the porous support by supplying a Pd-containing solution and a reducing feed material from opposite sides of the porous support.

Abstract: The method and the device for manufacturing an acoustically effective foil stack (9) made of embossed foil webs (5e, 5f, 5g, 5h) is characterised by the fact that at least two foil webs lying over one another (5a, 5b, 5c, 5d) are embossed at the same time, are conveyed along different length conveying routes (W, W1, W2, W3), and then are brought together into a stack (9), and embossed foil webs (5e, 5f, 5g, 5h) arranged to be lying next to one another are laid down in an offset fashion due to the different length conveying routes (W, W1, W2, W3). A particularly advantageous design of the embossing rollers (1a, 1b) provides foil webs which have knobs with a draped or folded type structure.

Abstract: A composite material and method of making the same are disclosed. An example method for fabricating a composite material forms a core layer between opposing outer layers. The core layer includes a mixture of at least one metallic powder and at least one expanding agent. The example method removes moisture and gasses from the core layer by applying a first vacuum pressure to at least the core layer. The example method compresses the core layer to bond the core layer to the outer layers while a second vacuum pressure is applied to at least one of the outer layers. The resulting composite material has a compacted core layer that is substantially free from moisture and imbedded gasses. Additionally, the outer layers are substantially free from perforations enabling the escape of gas and moisture during foaming of the core layer. The composite material may be reshaped to form semi-finished products which, in turn, may be heated to foam the core material to form finished products.

Abstract: The present invention is directed to nanoporous metal membranes and methods of making nanoporous metal membranes from metal leaf. At least a portion of the metal leaf is freely supported by a de-alloying medium for a time effective to de-alloy the metal leaf. After the porous membrane is formed, the membrane may be re-adhered to a substrate and removed from the de-alloying medium. The de-alloying process may be thermally and electrically influenced.

Abstract: A method of preparing the surface of a porous metal substrate to receive a membrane. The method does not substantially decrease the average bulk porosity of the metal substrate. A hydrogen separation membrane supported on the porous metal substrate. A cold spray is used to reduce surface variance. Exposure to an ion beam may also be used after application on the cold spray to prepare the surface of the substrate for membrane deposition.

Abstract: A method for reducing the surface variance of a porous metal substrate. The method does not significantly reduce the bulk porosity. The method can be used to reduce the surface pore diameter. A membrane, can be deposited on the reduced variance surface to form a separation membrane.

Abstract: A laminar structure (17) comprising a deposited metal, the structure having microholes (17a) extending between a first surface and a second surface thereof, each microhole having a wall which meets the first surface with a rounded edge or tapered configuration in such a manner that the first surface is substantially smooth.

Abstract: The present invention is directed to porous metal products including ceramic particles, where the initial surface layer (12) of the particles (10) is modified with agents that interact with surface oxygen, oxides and/or hydroxides to improve the wettability of particles within a molten metal alloy, and where the ceramic particles (10) are modified (14) by contacting the particles with a surface-modifying agent and heating the ceramic particles and surface-modifying agent to an elevated temperature at which the ceramic particle remains substantially stable and the surface-modifying agent becomes at least partially thermally unstable, to cause a reacted layer (16).

Abstract: In a semiconductor heat-dissipating substrate made of a Cu—W alloy whose pores have been infiltrated with copper, being a porous tungsten body whose pore diameter at a specific cumulative surface area of 95% is 0.3 &mgr;m or more, and whose pore diameter at a specific cumulative surface area of 5% is 30 &mgr;m or less, thermal conductivity of 210 W/m·K or more is obtained by decreasing the content of iron-family metal to be less than 0.02 weight %. Likewise, changing the amount of infiltrated copper in a molded object by utilizing a multi-shaft press to vary the amount of vesicles in the middle and peripheral portions makes for offering at low cost a semiconductor heat-dissipating substrate that in between middle and peripheral portions made of different materials does not have bonding matter.

Abstract: A gas turbine engine component includes a perforate metal wall having pores extending therethrough. The wall has a first surface covered by a thermal barrier coating. The pores have first ends which are covered by the thermal barrier coating, and the pores are ventilated from an opposite second surface of the wall for cooling the thermal barrier coating.

Abstract: A composite material with a porous inorganic-nonmetallic matrix and a second material, characterized in that

Abstract: Device and process for manufacturing a metal foam. The device includes at least two feed pipes for introducing gas. The at least two feed pipes are arranged next to one another. Each of the at least two feed pipes project into a foamable melt.

Abstract: A porous sintered metal comprising voids at least partially communicating with each other, and pores provided in walls of the voids, the porous sintered metal having a BET surface area of 700 cm2/cm3 or more, and an average diameter of the pores being 1 &mgr;m or more when measured by a mercury press-in method. The porous sintered metal is produced by blending a metal powder, a binder and resin particles to prepare a mixture in which the resin particles are dispersed; molding the mixture to provide a green body; selectively extracting the resin particles from the green body with a solvent; debinding the extracted green body by heating; and sintering the debound green body.

Abstract: Coating systems according to the prior art, wherein a ceramic layer is applied to a metallic layer of the coating system, the connection between metal and ceramic often being poor.

Abstract: A method of co-forming a metal article comprising forming a powdered metal component from a first powdered metal composition, providing a polymeric foam, coating the polymeric foam with a second powdered metal composition to form a coated polymeric foam, placing the coated polymeric foam in contact with the powdered metal component to form a composite, and heat-treating the composite to volatilize the polymeric foam and to solidify the powdered metal component. The powdered metal composition of the powdered metal component can be the same or different than the powdered metal composition used to coat the polymeric foam. The resulting co-formed metal article can be in a variety of configurations including, but not limited to, metal foam on the inside or outside surfaces of a metal tube and metal foam on one or more faces of a metal plate.

Abstract: There are provided a porous material and a process for producing the same. The porous material has a plurality of columnar pores and an area surrounding the pores, and the area is an amorphous area containing C, Si, Ge or a combination thereof.

Abstract: In a multi-layer armor system (10), useful for military vehicles, a metallic foam is provided as the shock energy-absorbing element. In a typical arrangement, the metallic foam shock-absorbing element (12) is sandwiched between a high strength strike plate (11) and a backing plate (13). Typically, the backing plate is a highly deforming metal, such as titanium, aluminum, or steel. However, the backing plate may comprise one or more layers of metal, ceramic or polymer-based composites. The high strength strike plate may be ceramic or metal. The shock-absorbing element is preferably a closed-cell metal foam with a high porosity that is effective in containing rearward deformation of the strike plate from a projectile strike. In a preferred embodiment, the shock-absorbing element is an aluminum foam with a porosity of 80 percent by volume.

Abstract: A bipolar plate for use with a fuel cell is provided including an electrically conductive foam as a coolant layer between thin metal foil layers. The thin metal foil layers are provided with serpentine flow field patterns on a surface thereof.