Inco Limited

Kirt Kenneth Cushnie

James A Bell

George Clayton Hansen

Anthony Edward Warner

Gaylord Darrell Smith

Victor A Ettel

John Ambrose

John J deBarbadillo, Ii

Eric Bain Wasmund

Scott Thomas Campbell

Vladimir Paserin

Raymond Augustus Bradford

Peter Joseph Kalal

Randal Mark Shaubel

Griffith Oswald Richard Williams

A continuous method for generating substantially submicron sized metal particles in a liquid dispersion of known viscosity. Metal carbonyl gas and an inert carrier gas, with an optional dilutant gas, are introduced into a heated liquid bath wherein the metal carbonyl decomposes into submicron sized pure metal particles. The particles are suspended in the liquid. The liquid is processed to form slurries and pastes.

Two experimental trials using the system 10 demonstrate the efficacy of the present process:

The method provides a process for fabricating metal matrix composites. First the process coats the fibers with nickel by electrodeposition or gaseous deposition to form nickel-coated fibers. Over-plating the nickel-coated fibers with aluminum by either electrodeposition in a non-aqueous electrolyte or gaseous deposition forms aluminum-coated-nickel-coated fibers. Sintering this product under compression, perpendicular to the fiber's central axis, forms the final metal matrix composite. The metal matrix composite has a nickel-aluminum matrix, very few voids and extended unbroken lengths of fibers within the nickel-aluminum matrix.

Method of forming metal matrix fiber composites

This process provides a method of fabricating porous aluminide articles. First the process consists of plating a preform with nickel and aluminum to create a metal-plated structure. The plating of nickel consists of electrodeposition or gaseous plating. The plating of aluminum consists of gaseous deposition of an organometallic-aluminum compound. The preform has either an open felt, woven fabric or a reticulated foam shape. Reactive sintering the metal-plated structure leaves an open nickel-aluminum structure having porosity and excellent strength and oxidation properties above 400.degree. C.

Method of preparing porous nickel-aluminum structures

The method of the invention produces nickel structures from nickel-coated polymer substrates. The nickel-coated polymer substrate has a nickel outer layer and initially has a temperature where the outer nickel layer lacks burst openings. Rapidly exposing the nickel-coated polymer substrate to a temperature of at least about 600.degree. C. thermally decomposes the polymer substrate and bursts holes through the outer nickel layer. The gases resulting from the thermally decomposed polymer substrate escape through the holes through the outer nickel layer to leave a nickel structure. Finally, annealing the nickel structure increases strength of the nickel structure to produce a ductile foam product.

Process for removal of polymer foams from nickel-coated substrates

A porous nickel electrode substrate having a central high conductivity core sandwiched between two layers of porous conductive material such as nickel foam or nickel felt. The porous conductive material is plated with nickel and then sintered. By selectively controlling the plating of nickel on the porous material, variable conductivities may be designed into the substrate.

Porous nickel electrode substrate

A gas turbine having internally cooled thermal barrier coated turbine blades is disclosed. The turbine blades are made from an alloy substrate exhibiting a low coefficient of thermal expansion, an intermediate bond coating and an exterior ceramic coating. Cooling fluid is supplied from the shaft of the compressor where it flows into and out of the turbine blade. Thermal barrier coated turbine blades result in more efficient gas turbine designs.

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Burlington, Canada

Kirt Kenneth Cushnie