An improved electrical contact alloy, useful for example, in vacuum interrupters used in vacuum contactors is provided. The contact alloy according to the disclosed concept comprises copper particles and chromium particles present in a ratio of copper to chromium particles of 2:3 to 20:1 by weight. The electrical contact alloy also comprises particles of a carbide, which reduces the weld break strength of the electrical contact alloy without reducing its interruption performance.

A heat transfer surface with a convective cooling layer includes a metal substrate and a porous metal foam layer transient liquid phase (TLP) bonded on the metal substrate. The porous metal foam layer includes a plurality of high melting temperature (HMT) particles and a plurality of micro-channels. A first TLP intermetallic layer is positioned between, and TLP bonds together, adjacent HMT particles to form the porous metal foam layer. A second TLP intermetallic layer is positioned between and TLP bonds a subset of the plurality of HMT particles to the metal substrate such that the porous metal foam layer is TLP bonded to the metal substrate. The plurality of micro-channels extend from an outer surface of the porous metal foam layer to the metal substrate such that a cooling fluid may be wicked through the plurality of micro-channels to the surface of the metal substrate.

Drill bits for use in drilling well bores in subterranean formations, and associated systems and methods of making and using such drill bits, are provided. In certain embodiments, the drill bits comprise: a body; a plurality of blades on the body; a plurality of cutting elements on at least one of the plurality of blades; a reinforcement material forming portions of the body and the plurality of blades; a binder material infiltrated through the reinforcement material to form a composite material and forming portions of the body and the plurality of blades; and at least one interior displacement element located in an interior region of the body that is surrounded by the composite material.

Drill bits for use in drilling well bores in subterranean formations, and associated systems and methods of making and using such drill bits, are provided. In certain embodiments, the drill bits comprise: a body; a plurality of blades on the body; a plurality of cutting elements on at least one of the plurality of blades; a reinforcement material forming portions of the body and the plurality of blades; a binder material infiltrated through the reinforcement material to form a composite material and forming portions of the body and the plurality of blades; and at least one interior displacement element located in an interior region of the body that is surrounded by the composite material.

A method of forming a leadless stack comprising multiple components is provided. The method comprises forming an MLCC comprising a first capacitor external termination and a second capacitor external termination and forming an electronic element is formed comprising a first element external termination and a second element external termination. The MLCC and electronic component are are arranged in a stack with a TLPS bond between the first capacitor external termination and the first element external termination.

A method for coating a body includes providing a plurality of granules in which each granule includes silicon (Si), carbon (C), chromium (Cr) and an iron group metal. The relative quantities of the Si, C and Cr are such that a molten phase will form at a melting temperature of less than 1,300 degrees Celsius when a threshold quantity of the iron group metal is accessible to the Si, C and Cr. A second source of the iron group metal is also provided. A combination of the granules and the second source is formed such that the threshold quantity of the iron group metal will be accessible to the Si, C and Cr. The granules and the second source are heated to the melting temperature to form the molten phase in contact with the body. The heat is then removed to allow the molten phase to solidify.

A method for coating a body includes providing a plurality of granules in which each granule includes silicon (Si), carbon (C), chromium (Cr) and an iron group metal. The relative quantities of the Si, C and Cr are such that a molten phase will form at a melting temperature of less than 1,300 degrees Celsius when a threshold quantity of the iron group metal is accessible to the Si, C and Cr. A second source of the iron group metal is also provided. A combination of the granules and the second source is formed such that the threshold quantity of the iron group metal will be accessible to the Si, C and Cr. The granules and the second source are heated to the melting temperature to form the molten phase in contact with the body. The heat is then removed to allow the molten phase to solidify.

There is disclosed a method for manufacturing an electrode by pressing and sintering a mixed powder of a solid solution powder of Cr and a heat-resistant element, which contains Cr and the heat-resistant element in a ratio such that Cr is greater than the heat-resistant element by weight, a Cu powder, and a low melting metal powder (Bi, Sn, Se, Pb, etc.). The low melting metal powder of 0.30 weight % to 0.50 weight % is added to a mixed powder of a solid solution powder of Cr and the heat-resistant element and the Cu powder, and then a mixed powder prepared by adding the low melting metal powder is sintered at a temperature of from 1010 C. to 1035 C. As the low melting metal powder, there is used a powder having a median size of from 5 m to 20 m.

There is disclosed a method for manufacturing an electrode by pressing and sintering a mixed powder of a solid solution powder of Cr and a heat-resistant element, which contains Cr and the heat-resistant element in a ratio such that Cr is greater than the heat-resistant element by weight, a Cu powder, and a low melting metal powder (Bi, Sn, Se, Pb, etc.). The low melting metal powder of 0.30 weight % to 0.50 weight % is added to a mixed powder of a solid solution powder of Cr and the heat-resistant element and the Cu powder, and then a mixed powder prepared by adding the low melting metal powder is sintered at a temperature of from 1010 C. to 1035 C. As the low melting metal powder, there is used a powder having a median size of from 5 m to 20 m.

A multilayer composite bonding material with a plurality of thermal stress compensation layers is provided. The plurality of thermal stress compensation layers include a metal core layer, a pair of particle layers extending across the metal core layer such that the metal core layer is sandwiched between the pair of particle layers, and a pair of metal outer layers extending across the pair of particle layers such that the pair of particle layers are sandwiched between the pair of metal outer layers. A pair of low melting point (LMP) bonding layers extend across the pair of metal outer layers. The metal core layer, the pair of particle layers, and the pair of metal outer layers each have a melting point above a transient liquid phase (TLP) sintering temperature, and the pair of LMP bonding layers each have a melting point below the TLP sintering temperature.