Ut-battelle, Inc.

Martin Marietta Energy Systems, Inc.

Lockheed Martin Energy Systems, Inc.

Innovation Services, Inc

The Babcock & Wilcox Company

Lockheed Martin Energy Research Corporation

Richard A Lowden

Joseph B Dooley

Thomas M McCoig

Jeffrey G Hubrig

Corson L Cramer

Norman L Vaughn

Cyrus M Smith

Amelia M Elliott

David P Stinton

Anthony J Caputo

Jacob W McMurray

Helen H Moeller

Charles E Devore

Kinga A Unocic

Jerry C McLaughlin

Trevor Aguirre

David Mitchell

Theodore M Besmann

Jeffrey Hubrig

A method of fabricating a refractory metal ceramic matrix interpenetrating phase harsh environment capable composite is provided. The method includes forming a reinforcing phase by additive manufacturing and introducing a matrix material to the reinforcing phase. The step of introducing the matrix material may be performed by additive manufacturing or a densification process. The reinforcing phase may be a lattice formed of metal or a ceramic, and the matrix material may be a ceramic or a metal. Alternatively, the reinforcing phase formed by additive manufacturing is a laminate layer, and the matrix material introduced to the reinforcing phase is a laminate layer deposited on the reinforcing phase by additive manufacturing in a plurality of alternating layers. A refractory metal ceramic matrix composite is also disclosed. The refractory metal ceramic matrix composite includes a lattice formed by additive manufacturing, and a matrix material deposited in the lattice.

Method of fabricating a refractory metal ceramic matrix composite

A method for indirect additive manufacturing of an object constructed of boron carbide, silicon carbide, and free silicon, comprising: (i) producing a porous preform constructed of boron carbide and silicon carbide by an indirect ceramic additive manufacturing (ICAM) process in which particles of a powder mixture become bonded together with an organic binder, wherein the powder mixture comprises: a) boron carbide particles, and b) silicon carbide particles, wherein at least 80 vol % of the silicon carbide particles are larger than the boron carbide particles; and wherein the boron carbide and silicon carbide particles are each included in an amount of 40-60 wt. % of the powder mixture, provided that the foregoing amounts sum to at least 95 wt. %; (ii) subjecting the porous preform to a temperature of 500-900&#xb0; C. to volatilize the organic binder; and (iii) infiltrating molten silicon into pores of the porous preform to produce the object.

Indirect additive manufacturing process for producing SiC&#x2014;B4C&#x2014;Si composites

A modular waste disinfection system for the disinfection of substantially liquid infectious waste streams and methods of treating such waste streams are disclosed. The modular waste disinfection system includes a metal ion generation chamber for introducing metal ions into the waste material; an oxidant generation chamber in fluid flow communication with the metal ion generation chamber for disinfection of the waste material with an oxidizing agent; and a chelation chamber in fluid flow communication with the oxidant generation chamber for deactivation of metal ions in the waste material, wherein the waste is discharged to a sanitary sewer after disinfection.

In-line waste disinfection method

A modular waste treatment system for substantially liquid waste streams and methods of treating liquid waste streams are disclosed. The modular waste treatment system includes a maceration chamber for initial treatment and homogenization of waste material; a metal ion infusion chamber in fluid flow communication with the maceration chamber for introducing metal ions into the waste material; and an oxidation chamber for wet oxidation of the waste stream.

Modular flameless waste treatment method

The method of making a non-lead hollow point bullet has the steps of a) compressing an unsintered powdered metal composite core into a jacket, b) punching a hollow cavity tip portion into the core, c) seating an insert, the insert having a hollow point tip and a tail protrusion, on top of the core such that the tail protrusion couples with the hollow cavity tip portion, and d) swaging the open tip of the jacket.

Method of making a non-lead hollow point bullet

The non-lead hollow point bullet of the instant invention comprises a mixed construction slug further comprising, a monolithic metal insert having a tapered (preferred conical) hollow point tip and a tapered (preferred conical) tail protrusion, and an unsintered powdered metal composite core in tandem alignment with the insert. The core has a hollow tapered (preferred conical) cavity tip portion coupled with the tapered (preferred conical) tail protrusion on the insert. An open tip jacket envelops at least a portion of the insert and the core. The jacket is swaged at the open tip.

Non-lead hollow point bullet

A solid object having controlled frangibility, such as a bullet or a container for explosives, is made by combining two different metals in proportions calculated to achieve a desired density, without using lead. A wetting material is deposited on the base constituent which is made of a relative dense, hard material. The wetting material enhances the wettability of the base constituent with the binder constituent, which is lighter and softer than the base constituent.

Non-lead, environmentally safe projectiles and explosives containers

A projectile, such as a bullet, is made by combining two different metals in proportions calculated to achieve a desired density, without using lead. A base constituent, made of a material having density greater than lead, is combined with a binder constituent having less density. The binder constituent is malleable and ductile metallic phase material that forms projectile shapes when subjected to a consolidation force, such as compression. The metal constituents can be selected, rationed, and consolidated to achieve desired frangibility characteristics.

Non-lead, environmentally safe projectiles and method of making same

A projectile, such as a bullet, is made by combining two different metals in proportions calculated to achieve a desired density, without using lead. A base constituent, made of a material having density greater than lead, is combined with a binder constituent having less density. The binder constituent is malleable and ductile metallic base material that forms projectile shapes when subjected to a consolidation force, such as compression. The metal constituents can be selected, rationed, and consolidated to achieve desired frangibility characteristics.

Non-lead environmentally safe projectiles and method of making same

Non-lead environmentally safe projectiles and explosive container

A process for chemical vapor deposition of crystalline silicon nitride which comprises the steps of: introducing a mixture of a silicon source, a molybdenum source, a nitrogen source, and a hydrogen source into a vessel containing a suitable substrate; and thermally decomposing the mixture to deposit onto the substrate a coating comprising crystalline silicon nitride containing a dispersion of molybdenum silicide.

Molybdenum enhanced low-temperature deposition of crystalline silicon

A filter for removing particulate matter from high temperature flowing fluids, and in particular gases, that is reinforced with ceramic fibers. The filter has a ceramic base fiber material in the form of a fabric, felt, paper of the like, with the refractory fibers thereof coated with a thin layer of a protective and bonding refractory applied by chemical vapor deposition techniques. This coating causes each fiber to be physically joined to adjoining fibers so as to prevent movement of the fibers during use and to increase the strength and toughness of the composite filter. Further, the coating can be selected to minimize any reactions between the constituents of the fluids and the fibers. A description is given of the formation of a composite filter using a felt preform of commercial silicon carbide fibers together with the coating of these fibers with pure silicon carbide. Filter efficiency approaching 100% has been demonstrated with these filters. The fiber base material is alternately made from aluminosilicate fibers, zirconia fibers and alumina fibers. Coating with Al.sub.2 O.sub.3 is also described. Advanced configurations for the composite filter are suggested.

Ceramic fiber reinforced filter

An improved cathode structure for Hall-Heroult cells for the electrolytic production of aluminum metal. This cathode structure is a preform fiber base material that is infiltrated with electrically conductive titanium diboride using chemical vapor infiltration techniques. The structure exhibits good fracture toughness, and is sufficiently resistant to attack by molten aluminum. Typically, the base can be made from a mat of high purity silicon carbide fibers. Other ceramic or carbon fibers that do not degrade at temperatures below about 1000 deg. C can be used.

Titanium diboride ceramic fiber composites for Hall-Heroult cells

An apparatus and process for the chemical vapor deposition of a matrix into a preform having circumferentially wound ceramic fibers, comprises heating one surface of the preform while cooling the other surface thereof. The resulting product may have fibers that are wound on radial planes or at an angle from the radial planes. The fibers can also be precoated with pyrolytic carbon before application of the matrix. The matrix is applied by passing reactant gas through the preform thereof to the other side thereof for the initial deposition of matrix near such other surface of the preform. The matrix fills in the preform from the other side surface thereof to the surface of the side of application thereof until a desired amount of matrix has been deposited.

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Clinton, TN, United States of America

Richard A Lowden