A system and method are provided to create porous surface coatings. In use, a surface material includes synthesized carbon-containing composite materials based on metallic particles and carbon particles, where the synthesized carbon-containing composite materials comprise a porosity characteristic, and satisfy at least one of: a heat transfer characteristic, a resistance to corrosion characteristic, or a non-ablative erosion characteristic. Additionally, the surface material includes a bonding layer disposed on a substrate to which the synthesized carbon-containing composite materials are bonded, and a surface layer comprising at least some of the synthesized carbon-containing composite materials, where a thermal characteristic of the surface layer is based on electron emissive cooling.

A method of treating a ceramic matrix composite article, including selecting an article having a ceramic composition formed by a process comprising an initial melt infiltration at an initial temperature with an initial infiltration material, whereby said article has at least one treatable feature. A portion of the ceramic composite is removed from a region abutting the treatable feature to form a treatment region. A treatment material including a reinforcing fiber is positioned in the treatment region and densified by a first melt infiltration with a first infiltration material including silicon. The first melt infiltration is performed at a first temperature lower than the initial infiltration temperature of the initial melt infiltration.

A method of treating a ceramic matrix composite article, including selecting an article having a ceramic composition formed by a process comprising an initial melt infiltration at an initial temperature with an initial infiltration material, whereby said article has at least one treatable feature. A portion of the ceramic composite is removed from a region abutting the treatable feature to form a treatment region. A treatment material including a reinforcing fiber is positioned in the treatment region and densified by a first melt infiltration with a first infiltration material including silicon. The first melt infiltration is performed at a first temperature lower than the initial infiltration temperature of the initial melt infiltration.

Disclosed are high strength tubular devices for use in oil and gas well drilling and completions, oil and gas well intervention, and/or production systems. The high strength tubular devices include a pipe component and a secondary layer on the surface of the pipe component. The secondary layer can be either a continuous or partial layer and includes a nanostructured alloy. Alloy compositions are disclosed. Methods for forming the tubular devices are disclosed. The secondary layer can be formed on the pipe component by welding or casting. The tubular devices can be used in conductors, casing, drill pipe, production tubing, pipeline and risers.

Disclosed are high strength tubular devices for use in oil and gas well drilling and completions, oil and gas well intervention, and/or production systems. The high strength tubular devices include a pipe component and a secondary layer on the surface of the pipe component. The secondary layer can be either a continuous or partial layer and includes a nanostructured alloy. Alloy compositions are disclosed. Methods for forming the tubular devices are disclosed. The secondary layer can be formed on the pipe component by welding or casting. The tubular devices can be used in conductors, casing, drill pipe, production tubing, pipeline and risers.

In some examples, an article for a high-temperature mechanical system including a substrate and a doped calcia-magnesia-alumina-silicate resistant (doped CMAS-resistant) layer on the substrate. The doped CMAS-resistant layer is a thermal barrier coating or an environmental barrier coating and includes a calcia dopant.

In some examples, an article for a high-temperature mechanical system including a substrate and a doped calcia-magnesia-alumina-silicate resistant (doped CMAS-resistant) layer on the substrate. The doped CMAS-resistant layer is a thermal barrier coating or an environmental barrier coating and includes a calcia dopant.

A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on the support to form the bulk material having insulated boundaries.

A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on the support to form the bulk material having insulated boundaries.

Presented are lithium-metal electrodes for electrochemical devices, systems and methods for manufacturing lithium-metal foils, and vehicle battery packs containing battery cells with lithium-metal anodes. A method of melt spinning lithium-metal foils includes melting lithium (Li) metal stock in an actively heated vessel to form molten Li metal. Using pressurized gas, the molten Li metal is ejected through a slotted nozzle at the base of the vessel. The ejected molten Li metal is directly impinged onto an actively cooled and spinning quench wheel or a carrier sheet that is fed across a support roller underneath the vessel. The molten Li metal is cooled and solidified on the spinning wheel/carrier sheet to form a Li-metal foil. The carrier sheet may be a polymeric carrier film or a copper current collector foil. An optional protective film may be applied onto an exposed surface of the Li-metal foil opposite the carrier sheet.