Systems and methods of synthesizing nanoparticles on substrates using rapid, high temperature thermal shock. A method involves depositing micro-sized particles or salt precursors on a substrate, and applying a rapid, high temperature thermal pulse or shock to the micro-sized particles or the salt precursors and the substrate to cause the micro-sized particles or the salt precursors to become nanoparticles on the substrate. A system may include a rotatable member that receives a roll of a substrate sheet having micro-sized particles or salt precursors; a motor that rotates the rotatable member so as to unroll consecutive portions of the substrate sheet from the roll; and a thermal energy source that applies a short, high temperature thermal shock to consecutive portions of the substrate sheet that are unrolled from the roll by rotating the first rotatable member. Some systems and methods produce nanoparticles on existing substrate. The nanoparticles may be metallic, ceramic, inorganic, semiconductor, or compound nanoparticles. The substrate may be a carbon-based substrate, a conducting substrate, or a non-conducting substrate. The high temperature thermal shock process may be enabled by electrical Joule heating, microwave heating, thermal radiative heating, plasma heating, or laser heating.

The disclosure provides a porous metal substrate structure with high gas permeability and redox stability for a SOFC and the fabrication process thereof, the porous metal substrate structure comprising: a porous metal plate composed of first metal particles; and a porous metal film composed of second metal particles and formed on the porous metal plate; wherein the porous metal plate has a thickness more than the porous metal film, and the first metal particle has a size more than the second metal particle. Further, a porous shell containing Fe is formed on the surface of each metal particle by impregnating a solution containing Fe in a high temperature sintering process of reducing or vacuum atmosphere, and the oxidation and reduction processes. The substrate uses the porous shells containing Fe particles to absorb the leakage oxygen.

Systems and methods for manufacturing sintered materials are disclosed. Metal nano- and microparticles can be sintered to form thin films. The metals are sintered in the presence of a binder such as a tar, e.g., steam cracker tar (SCT), which has strong absorbing and antioxidant properties that allow the metal particles to retain heat. Retention of heat by the binder can allow the sintering to occur at ambient temperatures. In some embodiments, the mixture and/or the resulting films can be used in additive manufacturing processes to build various components from the layers of thin film manufactured from the presently disclosed methods.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam core adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core; and securing an inlet fitting and an outlet fitting to the housing, wherein a thermal management fluid path for the internal component into and out of the housing is provided by the inlet fitting and the outlet fitting.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; and applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core.

A method for connecting components involves providing an arrangement of at least two components each containing at least one metallic contact surface and a metallic sintering agent in the form of a metallic solid body having metal oxide surfaces arranged between the components and pressuring sintering the arrangement whereby metal oxide surfaces of the metallic sintering agent and the metallic contact surfaces of the components each form a joint contact surface. The pressure sintering is carried out in an atmosphere containing at least one oxidizable compound and/or the metal oxide surfaces are provided with at least one oxidizable organic compound before formation of the corresponding joint contact surface.

A method for the production of a silver sintering agent in the form of a layer-shaped silver sintering body having silver oxide surfaces and the use thereof are provided.

Additive manufacturing structures and methods that enable the facile release of 3D printed parts are described. In one implementation, an additive manufacturing structure includes: a body; and a recessed section formed through a surface of the body, the recessed section comprising: a pour hole for filling the recessed section with a liquid metal or metal alloy that solidifies into an insert having a surface for forming a 3D object in a 3D printing device; and one or more air holes configured to release air displaced by the liquid metal or metal alloy.

Thermally decomposable build plates that enable the facile release of 3D printed parts are described. In one implementation, an additive manufacturing build plate comprises: a body including a top surface, a bottom surface, and sidewalls dimensioned such that the build plate is useable in a 3D printing device; and a layer of a solid metal or metal alloy on the top surface of the additive manufacturing build plate, the layer having a solidus temperature that is lower than a solidus temperature of the body, and the layer configured to provide a surface for forming a 3D object in the 3D printing device. In one implementation, an additive manufacturing build plate comprises a recessed section for receiving an insert including a layer of a solid metal or metal alloy on a surface of the insert.

A conductive material including a first element selected from a transition metal, a platinum-group element, a rare earth element, and a combination thereof, a second element having an atomic radius which is 10 percent less than to 10 percent greater than an atomic radius of the first element, and a chalcogen element, wherein the conductive material has a layered crystal structure.