A method for producing metal-based micro-porous structures includes continuously feeding a solid green part and a gas flow into a tunnel reactor having an aspect ratio greater than 2, wherein the solid green part has a characteristic diffusion mass transfer dimension less than 1 mm and a gas in the gas flow is substantially free of oxidants, and chemically reacting the gas in the gas flow and the green part under a predetermined temperature profile along a length of the tunnel reactor for a sufficient time to convert the green part into a solid product having pore sizes in a range of 0.3 nm to 5 μm.

This application relates to a method of manufacturing an electrostatic chuck having a high heat dissipation property and high thermal shock resistance and being lightweight, and an electrostatic chuck manufactured by the method. In one aspect, the method includes preparing a composite powder by milling (i) aluminum or aluminum alloy powder and (ii) carbon-based nanomaterial powder through ball milling. The method may also include manufacturing a multilayer billet including a core layer and one or more shell layers surrounding the core layer, in which at least one of the core and shell layers contains the composite powder. The method may further include extruding the multilayer billet to form an electrode layer and forming a dielectric layer on the electrode layer.

An aluminum base composite material contains an aluminum polycrystal body being a polycrystal body of a plurality of aluminum base material phases partitioned by a grain boundary, a carbon nanotube part being formed of a carbon nanotube or an aggregate thereof and being dispersed in at least one aluminum base material phase, and an alumina part being formed of alumina and being dispersed in at least one aluminum base material phase. The carbon nanotube preferably has a sphere-equivalent diameter from 10 nm to 300 nm, and the number of the carbon nanotube part that is present in a cross-sectional area of 200 μm.sup.2 of the aluminum base composite material is preferably one or more.

An aluminum base composite material contains an aluminum polycrystal body being a polycrystal body of a plurality of aluminum base material phases partitioned by a grain boundary, a carbon nanotube part being formed of a carbon nanotube or an aggregate thereof and being dispersed in at least one aluminum base material phase, and an alumina part being formed of alumina and being dispersed in at least one aluminum base material phase. The carbon nanotube preferably has a sphere-equivalent diameter from 10 nm to 300 nm, and the number of the carbon nanotube part that is present in a cross-sectional area of 200 μm.sup.2 of the aluminum base composite material is preferably one or more.

An apparatus and process are presented for continuous production of metal-based micro-porous structures of pore sizes from 0.3 nm to 5.0 μm from a green part of characteristic diffusion mass transfer dimension less than 1 mm through chemical reactions in a continuous flow of gas substantially free of oxygen. The produced micro-porous structures include i) thin porous metal sheets of thickness less than 200 μm and pore sizes in the range of 0.1 to 5.0 μm, ii) porous ceramic coating of thickness less than 40 μm and ceramic particle sizes of 200 nm or less on a porous metal-based support structures of pore sizes in the range of 0.1 to 5 μm.

An aluminum-based composite material includes a plurality of coarse crystalline grains (3) of pure aluminum, and a plurality of fine crystalline grains (4) each having an aluminum matrix (1), and a dispersion material (2) dispersed inside the aluminum matrix and formed by reacting a portion or all of an additive with aluminum in the aluminum matrix. The fine crystalline grains exist among the coarse crystalline grains, and the fine crystalline grains have crystalline grain diameters smaller than crystalline grain diameters of the coarse crystalline grains.

Disclosed are a method of manufacturing a billet used in plastic working for producing a composite member and a billet manufactured by the method. The method includes (A) ball-milling powders of two more materials to prepare a composite powder and (B) preparing a multi-layered billet containing the composite powder. The multi-layered billet includes a core layer and two or more shell layers. The shell layers except for the outermost shell layer are made of the composite powder. The outermost shell layer is made of a pure metal or metal alloy. The composite powders contained in the core layer and each of the shell layers have different compositions. The method has an advantage of manufacturing a plastic working billet being capable of overcoming the limitation of a single-material billet and enabling production of a characteristic-specific composite member such as a clad member.

A structured multi-phase composite which include a metal phase, and a low stiffness, high thermal conductivity phase or encapsulated phase change material, that are arranged to create a composite having high thermal conductivity, having reduced/controlled stiffness, and a low CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured multi-phase composite is useful for use in structures such as, but not limited to, high speed engine ducts, exhaust-impinged structures, heat exchangers, electrical boxes, heat sinks, and heat spreaders.

A solid-state manufacturing method comprising urging a metal-based feedstock material within a sleeve of a propulsion system in a processing direction along an axis of the sleeve and against a friction die adjacent one end of the sleeve; softening at least a portion of the feedstock material within the hollow portion of the sleeve to a malleable state to form malleable feedstock material using relative rotatory friction between the friction die and the feedstock material; extruding the malleable feedstock material from an extrusion hole in response to the urging step; and depositing the malleable feedstock material from the extrusion hole onto a substrate as a paste using at least one plastering surface and continuing depositing the malleable feedstock material as deposit layers until a desired shape is completed.

A solid-state manufacturing method comprising urging a metal-based feedstock material within a sleeve of a propulsion system in a processing direction along an axis of the sleeve and against a friction die adjacent one end of the sleeve; softening at least a portion of the feedstock material within the hollow portion of the sleeve to a malleable state to form malleable feedstock material using relative rotatory friction between the friction die and the feedstock material; extruding the malleable feedstock material from an extrusion hole in response to the urging step; and depositing the malleable feedstock material from the extrusion hole onto a substrate as a paste using at least one plastering surface and continuing depositing the malleable feedstock material as deposit layers until a desired shape is completed.