Some variations provide a system for producing a functionalized powder, comprising: an agitated pressure vessel; first particles and second particles contained within the agitated pressure vessel; a fluid contained within the agitated pressure vessel; an exhaust line for releasing the fluid from the agitated pressure vessel; and a means for recovering a functionalized powder containing the second particles disposed onto surfaces of the first particles. A preferred fluid is carbon dioxide in liquefied or supercritical form. The carbon dioxide may be initially loaded into the pressure vessel as solid carbon dioxide. The pressure vessel may be batch or continuous and is operated under reaction conditions to functionalize the first particles with the second particles, thereby producing a functionalized powder, such as nanofunctionalized metal particles in which nanoparticles act as grain refiners for a component ultimately produced from the nanofunctionalized metal particles. Methods for making the functionalized powder are also disclosed.

A method of producing metallic sodium powders. The method includes immersing one or more solid pieces of sodium metal in an organic liquid containing a hydrocarbon oil. The solid piece(s) of sodium metal immersed in the hydrocarbon oil is (are) then subjected to ultrasonic irradiation, wherein the solid piece of sodium metal is fragmented to form sodium powder, resulting in a dispersion of the sodium powder in the organic liquid. The dispersed sodium powder is then separated from the organic liquid, resulting in metallic sodium powder. A method of presodiation of an anode in an electrochemical cell. The method includes adding sodium metal powders to the surface of the anode either as a dry powder or as a suspension of the sodium particles in an organic liquid. An anode in an electrochemical cell containing metallic sodium particles. An electrochemical cell comprising a presodiated anode.

A method of producing metallic sodium powders. The method includes immersing one or more solid pieces of sodium metal in an organic liquid containing a hydrocarbon oil. The solid piece(s) of sodium metal immersed in the hydrocarbon oil is (are) then subjected to ultrasonic irradiation, wherein the solid piece of sodium metal is fragmented to form sodium powder, resulting in a dispersion of the sodium powder in the organic liquid. The dispersed sodium powder is then separated from the organic liquid, resulting in metallic sodium powder. A method of presodiation of an anode in an electrochemical cell. The method includes adding sodium metal powders to the surface of the anode either as a dry powder or as a suspension of the sodium particles in an organic liquid. An anode in an electrochemical cell containing metallic sodium particles. An electrochemical cell comprising a presodiated anode.

An electrically conductive composite powder is provided for microwave shielding applications. The electrically conductive composite powder includes a core of particles formed from a material having a low density of <5 g/cm.sup.3 and a high dielectric constant of ≥10; an intermediate layer coated onto the core of particles, wherein said intermediate layer has a high electrical conductivity of >5.90×10.sup.−8 Ohm*m at 20° C.; and an outer layer that is deposited onto the intermediate layer, said outer layer comprising a material having a high oxidation and corrosion resistance of >−0.2V galvanic potential in seawater as measured via ASTM G82. The electrically conductive composite powder exhibits excellent microwave shielding performance, while also being substantially lower in cost that conventional Ag/Ni shields. The electrically conductive composite powder can be used across a broad microwave frequency range.

An electrically conductive composite powder is provided for microwave shielding applications. The electrically conductive composite powder includes a core of particles formed from a material having a low density of <5 g/cm.sup.3 and a high dielectric constant of ≥10; an intermediate layer coated onto the core of particles, wherein said intermediate layer has a high electrical conductivity of >5.90×10.sup.−8 Ohm*m at 20° C.; and an outer layer that is deposited onto the intermediate layer, said outer layer comprising a material having a high oxidation and corrosion resistance of >−0.2V galvanic potential in seawater as measured via ASTM G82. The electrically conductive composite powder exhibits excellent microwave shielding performance, while also being substantially lower in cost that conventional Ag/Ni shields. The electrically conductive composite powder can be used across a broad microwave frequency range.

Disclosed herein is a method for reducing a metal oxide in a metal containing precursor. The method comprises providing a reaction mixture comprising the metal oxide containing precursorand an aluminium reductant; heating the reaction mixture in the presence of solid or gaseous aluminium chloride to temperature at which reactionsthatresultin the metal oxide being reduced are initiated; controlling reaction conditions whereby the reaction mixture is prevented from reaching a temperature at which thermal runaway can occur; and isolating reaction products that include reduced metal oxide.

Disclosed herein is a method for reducing a metal oxide in a metal containing precursor. The method comprises providing a reaction mixture comprising the metal oxide containing precursorand an aluminium reductant; heating the reaction mixture in the presence of solid or gaseous aluminium chloride to temperature at which reactionsthatresultin the metal oxide being reduced are initiated; controlling reaction conditions whereby the reaction mixture is prevented from reaching a temperature at which thermal runaway can occur; and isolating reaction products that include reduced metal oxide.

Disclosed herein are nanostructured electrodes and methods of making and use thereof. The nanostructured precursor electrodes comprising a copper substrate, a nanostructured copper oxide layer disposed on the copper substrate and a nickel layer disposed on the nanostructured copper oxide layer.

A method for forming a crystalline metal layer on a three-dimensional (3D) substrate is provided. The method includes applying crystal growth ink to a surface of the 3D substrate, wherein the crystal growth ink includes a metal ionic precursor and a structuring liquid; and exposing the 3D substrate to plasma irradiation from plasma in a vacuum chamber to cause the growing of a crystalline metal layer on the 3D substrate, wherein the exposure is based on a set of predefined exposure parameters.

A method for forming a crystalline metal layer on a three-dimensional (3D) substrate is provided. The method includes applying crystal growth ink to a surface of the 3D substrate, wherein the crystal growth ink includes a metal ionic precursor and a structuring liquid; and exposing the 3D substrate to plasma irradiation from plasma in a vacuum chamber to cause the growing of a crystalline metal layer on the 3D substrate, wherein the exposure is based on a set of predefined exposure parameters.