IP Library Granted Patent US 7,214,280
Granted Patent B2
US 7,214,280 · App. 10/430,416 · Granted May 8, 2007

Plasma-assisted decrystallization

Assignee: BTU International Inc.
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Quick Facts
Patent No.
US 7,214,280
App. No.
10/430,416
Granted
May 8, 2007
Kind
B2
Abstract

Methods and apparatus are provided for igniting, modulating, and sustaining a plasma for at least partially decrystallizing a surface of an object. In one embodiment, a method is provided for decrystallizing a surface of an object by forming a plasma (such as by subjecting a gas to an amount of electromagnetic radiation, optionally in the presence of a plasma catalyst) and exposing the surface of the object to the plasma.

Claims (50)

1. A method of decrystallizing a surface of an object comprising:

initiating a microwave plasma at substantially atmospheric conditions; by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst;

exposing the surface to the plasma for a period of time sufficient to at least partially decrystallize the surface;

wherein the exposing comprises directing electromagnetic radiation into a cavity, wherein the directing is selected from a group consisting of continuously directing, periodically directing, programmed directing, and any combination thereof; and

controlling a temperature associated with the plasma according to a predetermined temperature profile by varying at least one of a gas flow through the cavity and an electromagnetic radiation density near the surface of the object.

2. The method of claim 1 , wherein the plasma catalyst is passive plasma catalyst.

3. The method of claim 2 , wherein the catalyst is in the form of at least one of a nano-particle, a nano-tube, a powder, a dust, a flake, a fiber, a sheet, a needle, a thread, a strand, a filament, a yarn, a twine, a shaving, a sliver, a chip, a woven fabric, a tape, and a whisker.

4. The method of claim 2 , wherein the plasma catalyst includes at least one of x-rays, gamma radiation, alpha particles, beta particles, neutrons, protons, arid any combination thereof.

5. The method of claim 2 , wherein the plasma catalyst includes at least one of electrons and ions.

6. The method of claim 1 , wherein the catalyst comprises at least one of metal, inorganic material, carbon, carbon-based alloy, carbon-based composite, electrically conductive polymer, conductive silicone elastomer, polymer nanocomposite, and an organic-inorganic composite.

7. The method of claim 6 , wherein the catalyst is in the form of at least one of a nano-particle, a nano-tube, a powder, a dust, a flake, a fiber, a sheet, a needle, a thread, a strand, a filament, a yarn, a twine, a shaving, a sliver, a chip, a woven fabric, a tape, and a whisker.

8. The method of claim 6 , wherein the catalyst comprises carbon fiber.

9. The method of claim 1 , wherein the directing comprises sustaining the plasma.

10. The method of claim 1 wherein the directing comprises directing the electromagnetic radiation along a path, such that a plasma catalyst is located at some point along the path.

11. The method of claim 1 , wherein the exposing is at a location, the method further comprising moving the surface relative to the location by a moving method elected from a group consisting of periodically moving, continuously moving, programmed moving, and any combination thereof.

12. The method of claim 11 , wherein the object is a metal, the method further comprising shaping the metal before the exposing.

13. The method of claim 1 , wherein the period of time is less than about 25 minutes.

14. The method of claim 13 , wherein the period of time is less than about 120 seconds.

15. The method of claim 14 , wherein the period of time is less than about 10 seconds.

16. The method of claim 1 , wherein, during the exposing, the electromagnetic radiation has a time-averaged power density in the plasma greater than about 1 W/cm 3 .

17. The method of claim 16 , wherein the time-averaged power density is greater than about 10 W/cm 3 .

18. The method of claim 1 , wherein the exposing is performed such that the surface of the object is positioned adjacent to a magnetic field vector maximum.

19. The method of claim 1 , wherein the exposing comprises exposing the surface in a plurality of plasma bursts.

20. The method of claim 1 , wherein the exposing is in a substantially single-mode cavity.

21. The method of claim 1 , wherein the plasma catalyst is an active plasma catalyst.

22. The method of claim 1 , wherein the directing comprises modulating the plasma.

23. A method of decrystallizing a surface of an object comprising:

initiating a microwave plasma at substantially atmospheric conditions;

exposing the surface to the plasma for a period of time sufficient to at least partially decrystallize the surface; and

directing a laser beam at the surface during the exposing.

24. A method of decrystallizing a surface of an object comprising:

initiating a microwave plasma at substantially atmospheric conditions;

exposing the surface to the plasma for a period of time sufficient to at least partially decrystallize the surface;

wherein the exposing is performed such that the surface of the object is positioned adjacent to a magnetic field vector maximum; and

wherein the vector maximum has a direction that is substantially perpendicular to the surface.

25. A method of decrystallizing a surface of an object comprising:

initiating a microwave plasma at substantially atmospheric conditions;

exposing the surface to the plasma for a period of time sufficient to at least partially decrystallize the surface;

wherein the object is a ceramic.

26. A method of decrystallizing a surface of an object comprising:

initiating a microwave plasma at substantially atmospheric conditions;

exposing the surface to the plasma for a period of time sufficient to at least partially decrystallize the surface; and

wherein the object is composed of tungsten carbide.

27. A method of decrystallizing a surface of an object comprising:

initiating a microwave plasma at substantially atmospheric conditions;

exposing the surface to the plasma for a period of time sufficient to at least partially decrystallize the surface;

wherein the exposing is at a location, the method further comprising moving the surface relative to the location by a moving method selected from a group consisting of periodically moving, continuously moving, programmed moving, and any combination thereof; and

wherein the object is a ceramic.

28. The method of claim 27 , further comprising the step of shaping the ceramic before the exposing.

29. The method of claim 27 , wherein the ceramic is composed of tungsten carbide.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 12, 2006
From: DANA CORPORATION
To: BTU INTERNATIONAL INC.
Reel/Frame 017777/0430 →
Continuity (4)
Provisional Application 6043527800 · Dec 23, 2002
Provisional Application 6043067700 · Dec 4, 2002
Provisional Application 6037869300 · May 8, 2002
Related Publication 20040107896A1 · Jun 10, 2004