APS Materials, Inc.

A Spark of Creativity...

Patented Heat-Resistant Exhaust Manifold
In automobiles, heat generated from exhaust manifolds causes degeneration in various engine components as well as the manifold itself. Many varied types of heat shields and insulation have been employed in attempt to alleviate this problem. Ongoing efforts continue to channel the maximum possible amount of heat from the exhaust ports of the cylinder heads through the exhaust system, minimizing the amount of heat releases in the engine compartment. APS Materials, Inc. obtained a patent in 1990 for a superior exhaust manifold and process of lining manifolds that results in greater insulation, fuel efficiency as well as lowered exhaust emissions. The manifold is constructed of two or more sections lined with a heat resistant material containing zirconium and/or ceramics. The APS process is used to apply the compound in layers .010-.0150 inches thick.

DC Arc-Plasma Fabrication of Tungsten Piping and
Tubing for Improved Nuclear Fuel Cycle Processes
At Argonne National Labs, tungsten tubing is needed to transfer of molten uranium. Several researchers at APS Materials and Drexel University’s Center for Processing of Materials realized that a potential answer to this problem was the direct fabrication of tungsten tubing using low pressure plasma spraying (LPPS). This process demonstrated that pipes or tubes of tungsten can be fabricated in a range of diameters and that these items have the proper metallurgical and mechanical properties to serve as transfer lines for nuclear fuel cycle processes. Plasma spray eliminates the leaks and corrosion caused by enlarged grain resulting from competitive deposition processes and minimized the inclusion of oxides. The tubes are constructed as "near-net shapes", a single part constructed of a thermal sprayed material over a removable substrate. In this case, copper was used as the removable mandrel, and then two separate tubes were joined together using thermal spray.

Ceramic Fiber Composite Thermal Barrier Coating
In 1990, APS Materials and the U.S. Navy continued a yearlong study of the use of ceramic fibers in thermal barrier coatings. These fibers served as strengthening agents that enhanced the lifetimes of thermal barrier coatings. Fibers tested were mullite, SiC, zirconia, and others in a shrouded plasma spray process. The study included the construction of a modified design of a previous burner rig that adapted improvements to temperature and cycle time controls as well as data acquisition. We were particularly interested in the incorporation of fibers within the bondcoat/topcoat interface since previous data showed significant lifetime improvements with this approach.

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