Thermionic energy conversion in a miniature format shows potential as a viable, high efficiency, micro to macro-scale power source. A microminiature thermionic converter (MTC) with inter-electrode spacings on the order of microns has been prototyped and evaluated at Sandia. The remaining enabling technology is the development of low work function materials and processes that can be integrated into these converters to increase power production at modest temperatures (800 -1300 K). The electrode materials are not well understood and the electrode thermionic properties are highly sensitive to manufacturing processes. Advanced theoretical, modeling, and fabrication capabilities are required to achieve optimum performance for MTC diodes. This report describes the modeling and fabrication efforts performed to develop micro dispenser cathodes for use in the MTC. Figure 24. A time progression from a simulation of microstructure coarsening in a layered twophase material. The simulation grid has 100x100x100 points, the interfacial energy between the two phases is one, the time increment is ∆t = 1, and the temperature is T = 2. The images, starting from top left and progressing to the right, are from simulation times of 0, 2000, 4000, 6000, 8000, 10000, 12000, 14000, 16000, 18000, 20000, 22000, 24000, 26000, 28000, 30000, 40000, 100000, 200000, and 300000. 37 Figure 25. Examples of site exchange paths in a two-dimensional system containing a strip of one phase embedded in a matrix of another. The energy change involved in reaching each configuration is written in white text at the lower right of each frame. 38 Figure 26. A time progression from a simulation of microstructure coarsening in a layered twophase material with a diffusing surfactant. The simulation grid has 200x200x200 points, the interfacial energy between the two phases is one, the time increment is ∆t = 0.5, and the temperature is T = 3. The images, starting from top left and progressing to the right, are from simulation times of 0, 100, 200, 400, 600, 1000, 1400, 1800, 2200, 2400, 2600, 2800, 3000, 3300, 3600, 3900, 4200, and 4500. 39 Figure 27. Evolution of surfactant concentration from a midplane source. The simulation grid has 200x200x200 points and the time increment between diffusion steps is 0.5. The images, starting from top left and progressing to the right, are from simulation times of 0, 100, 200, 400, 600, 1000, 1400, 1800, 2200, 2400, 2600, 2800, 3000, 3300, 3600, 3900, 4200, and 4500. 40 Figure 28. A time progression from a simulation of simultaneous microstructure coarsening and chemical reaction in a layered two-phase material. The simulation grid has 96x96x96 points, the time increment is t = 0.5, and the temperature is T = 3. The images, starting from top left and progressing to the right, are from simulation times of 0, 100, 200, 300, 400, 500, 600, and 700. In the nomenclature of Tables 1 and 2, the blue sites are species A, the red are B, and the green are C. The interfacial energies are E AB = 1, E AC = 0.8, E AO = 1, E BC = 0....