Ultralow density ionic material foams, with density approaching 0.1% of the bulk density, and synthesis methods using interconnected metallic nanowires are provided. Nanowires of various sizes and metals are dispersed into a freezable liquid through a suitable fluid exchange. Surface treatments ensure that nanowires remain sufficiently metallic and physically separated. Wire-liquid solutions can be dropped directly into liquid nitrogen in the form of droplets or placed into molds of various shapes. A freeze drying technique is employed to turn the resulting ice-wire mixture into a freestanding, low-density foam composed of interlocked nanowires. Sintering or oxidation and reduction treatment of the foam material at elevated temperatures is used to connect the nanowires into an interconnected metallic foam. Metals of the metal foams are then processed into ionic materials including oxides, nitrides, chlorides, hydrides, fluorides, iodides and carbides.

A method of fabricating an article includes providing an arrangement of loose nanowires, forming the loose nanowires into a gas turbine engine airfoil by depositing the loose nanowires into a mold that has a geometry of the gas turbine engine airfoil, and bonding the loose nanowires together into a unitary cellular structure that has the geometry of the gas turbine engine airfoil.

A method of fabricating an article includes providing an arrangement of loose nanowires, forming the loose nanowires into a gas turbine engine airfoil by depositing the loose nanowires into a mold that has a geometry of the gas turbine engine airfoil, and bonding the loose nanowires together into a unitary cellular structure that has the geometry of the gas turbine engine airfoil.

The present invention refers to a method for preparing a network of nanowires; to a network of nanowires obtainable by said method; to a nonwoven material comprising the network, to an electrode comprising the network, to the use of the network of nanowires and to the use of the nonwoven material.

The invention concerns the production of segmented nanowires and components having said segmented nanowires. For the production of the nanowire structural element, a template based process is used preferably, wherein the electrochemical deposition of the nanowires in nanopores is carried out. In this manner, numerous nanowires are created in the template foil. For the electrochemical deposition of the nanowires, a reversed pulse procedure with an alternating sequence consisting of cathodic deposition pulses and anodic counter-pulses is carried out. By this means, segmented nanowires can be produced.

Some embodiments of the present disclosure relate to additively manufactured vehicle exterior structures, designed to enclose the vehicle surface and support required operational loads. The vehicle structure includes cavities into which components that require an external interface are inserted. A plurality of components are assembled and integrated into the vehicle structure. The structure may be 3-D printed using multiple printing techniques applied in parallel or in series. In an embodiment, the components and structure are modular, use multiple materials and manufacturing techniques, and enable reparability and replacement of single parts.

Some embodiments of the present disclosure relate to an additively manufactured transport structure. The transport structure includes cavities into which components that use an external interface are inserted. A plurality of components are assembled and integrated into the vehicle. In an embodiment, the components and frame are modular, enabling reparability and replacement of single parts in the event of isolated failures.

A method of forming a bulk product includes the step of coating a particulate conductive phase material with a binder phase, and forming the coated conductive phase material into at least one of sheet stock, tape formed into a bulk material. A method of forming a bulk product includes the step of coating a particulate conductive phase material with a binder phase and forming the coated conductive phase material into a bulk material. The conductive phase material includes at least one of two dimensional materials, single layer materials, carbon nanotubes, boron nitride nanotubes, aluminum nitride and molybdenum disulphide (MoS.sub.2). A component is also disclosed.

A nanofiber based micro-structured material including metal fibers with metal oxide coatings and methods are shown. In one example, nanofiber based micro-structured material is used as an electrode in a battery, such as a lithium ion battery, where the nanofibers of micro-structured material form a nanofiber cloth with free-standing, core-shell structure.

A fiber-reinforced cutting element for a drill bit and method of manufacturing same is disclosed. A plurality of fibers are formed in and embedded between the PCD table and the attached substrate. The fibers enhance the thermo-mechanical integrity of the cutting element as well as its wear and abrasion resistance and also help to minimize the failure of the bond between the PCD table and the substrate. The fibers may be coated with a ceramic material to help withstand the high temperatures during the HTHP sintering process used to form the PCD table. The PCD table is leached following the HTHP press cycle thereby partially exposing the fibers. The PCD table with partially exposed fibers is then bonded to a substrate through an infiltration, hot pressing or sintering process. A binder may optionally be used to enhance the binding of the substrate to the PCD table.