1. Plasma Processes, Inc. Scott O’Dell12/3/20021 Introduction Plasma Processes, Inc. is a small business that specializes in the development and fabrication of refractory metals and advanced ceramic materials for High Heat Flux (HHF) applications. Innovative Vacuum Plasma Spray (VPS) forming techniques are used to produced complex configurations. As a result of recent advancements, engineered tungsten surfaces for IFE dry chamber walls that eliminate helium build-up are a possibility.

2. Plasma Processes, Inc. Scott O’Dell12/3/20022 Examples of VPS Formed Tungsten Components Plasma facing component heat sinks with in-situ formed helical fins Thin-walled closed end cartridges for processing samples in microgravity (leak rate of <1x10 -8 sccs He) Nozzle inserts to reduce/eliminate throat erosion solid rocket engines.

3. Plasma Processes, Inc. Scott O’Dell12/3/20023 Micrographs of VPS Tungsten Deposits Using Micron Size Starting Powders A BC Average starting particle size: A) 26  m B) 13  m C) 3  m Micrographs demonstrate by reducing the starting powder size the grain structure of the resulting deposit can be reduced.

4. Plasma Processes, Inc. Scott O’Dell12/3/20024 Nanostructured Materials Development To date, nanostructured alumina components have been fabricated. Bright field TEM images of plasma sprayed alumina (A) alumina grains <100nm size and (B) lattice fringes indicating 20nm subdomains within the nanosize particles. AB

5. Plasma Processes, Inc. Scott O’Dell12/3/20025 Nanostructured Tungsten Development PPI is currently developing innovative techniques for producing nanostructured tungsten components using nanosized tungsten and hafnium carbide starting powders. The goal of this effort is to evaluate the affect ultrafine grains will have on the mechanical and physical properties of tungsten. To prevent coarsening of the nanosized tungsten during fabrication and subsequent high temperature usage, hafnium carbide is being added to pin the tungsten grain boundaries. Fabrication of samples for analysis is expected before the end of 2002.