Abstract: The present invention pertains to an electronic package. The package has an internal portion having reinforcement, which is infiltrated with metal. There is a pure metal skin about the internal portion such that the internal portion is hermetically sealed. The metal skin is comprised purely of the metal infiltrated within the reinforcement and forms a continuum with the metal within the reinforcement.

Abstract: The present invention is a method of cooling. The method comprises the steps of positioning material in a liquid state within a chamber. Then, there is the step of providing pressurized fluid about the chamber to form a thermal gradient across the chamber to directionally cool the material within. Preferably, the positioning step includes the step of positioning a mold with a mold chamber having material in a liquid state in the mold chamber, within an interior of a pressure vessel. Preferably, the providing step includes the step of introducing fluid, such as gas, into the pressure vessel such that the fluid that initially enters the pressure vessel is heated to a greater temperature than fluid subsequently introduced into the pressure vessel due to the fluid absorbing heat from the interior of the pressure vessel.

Abstract: The apparatus for casting comprises a pressure vessel and a device for pressurizing the vessel. The pressurizing device is in fluidic connection with the vessel. The apparatus is also comprised of a chamber disposed in the pressure vessel within which material is melted. There is a mold adapted to contain a preform disposed in the vessel and in fluidic connection with the chamber by a passage such that melted material in the chamber can be forced down into the mold through the passage as the pressurizing device pressurizes the vessel. A heating device is disposed in the vessel. There is also a device for directionally solidifying the material in the mold. Additionally, there is a method comprising the steps of loading the pressure vessel by disposing a material within the chamber whereby the material is in fluidic connection with the mold adapted to contain a preform through the passage. The passage has a filter disposed therein.

Abstract: The present invention pertains to a system for casting a melted material. The system has a mold having a mold cavity for forming the melted material. There is a coating disposed about the mold cavity which chemically reacts with the melted material such that the melted material cannot react with mold. In this manner, the cast part can be more easily released from the mold, since it cannot chemically react with it. The present invention is also a method of casting a melted material. The method comprises the step of coating a mold cavity of a mold with a material which is chemically reactive with the melted material. Next, there is the step of introducing melted material into the mold cavity such that melted material infiltrates and chemically reacts with the material on the mold to form a composite skin which prevents the melted material from chemically reacting with the mold. Then, there can be the step of cooling the melted material.

Abstract: The present invention pertains to an apparatus for casting which includes a melt chamber within which a metal is disposed. The melt chamber includes means for melting the material. A mold chamber is disposed beneath the melt chamber comprised of a mold defining a mold cavity within which the metal is formed and a preform is disposed. There is also a riser cavity fluidically connected to the mold cavity for holding a charge of melted metal. There is also provided means for fluidically connecting the melt chamber to the mold chamber and a valve element for controlling the flow of metal through the connecting means such that when the connecting means is opened, the chambers are fluidically connected and when the connecting means is closed, the chambers are fluidically isolated. The mold chamber has means for evacuating the mold chamber and means for pressurizing the mold chamber such that the melted metal disposed within the riser cavity is forced into the preform.

Abstract: The present invention pertains to a method of forming a metal matrix composite. The method comprises the steps of surrounding at least one insert with reinforcement material. Next, there is the step of orienting the insert and reinforcement within a mold. Then, there is the step of infiltrating the mold with liquid metal such that the reinforcement material around the insert is infiltrated. In a preferred embodiment, the insert comprises a hollow core and closed ends and the surrounding step includes the step of wrapping reinforcement around the insert. Preferably, the hollow core is exposed and the insert is leached out with the appropriate leaching solution.

Abstract: The present invention is a method for casting and densification. The method is comprised of the steps of filling a mold in a pressure vessel to a predetermined level with molten metal and then increasing the pressure in the vessel such that voids formed within the metal are substantially closed without removing the mold with the metal from the pressure vessel. Preferably, after the increasing pressure step, there is the step of cooling the molten metal to ambient temperatures. In one embodiment, the increasing pressure step includes the step of increasing pressure in the vessel at a predetermined rate through the liquidus, liquidus/solidus and solidus phases of the metal. Alternatively, the increasing pressure step can include the step of increasing pressure at a predetermined rate through the liquidus/solidus and solidus phase of the metal. Alternatively, the increasing pressure step can include the step of increasing pressure at a predetermined rate through the solidus phase of the metal.

Abstract: A method for forming a metal matrix composite within a mold of investment material. The method comprises the steps of forming a preform mixture of liquid flow medium, binding agent and reinforcement into the desired shape of a metal matrix composite. Then, allowing the preform mixture to solidify into desired shape. Next, encasing the preform mixture within a container of investment material. Then, heating the preform mixture at a controlled rate which first allows any fluid, such as water, to evaporate, then allows removal of the flow medium. Next, sintering the remaining reinforcement material and binder to form a solid preform. Then, disposing molten metal on top of the solid preform within the container such that the molten metal forms a seal with the container. Next, pressurizing the molten metal such that it is forced into said preform. Next, solidifying the molten metal to form a metal matrix composite in the shape of this preform; and removing the investment material from metal matrix composite.

Abstract: A porous preform is placed in a nonporous mold chamber of a pressure vessel. A material is placed in a crucible of the pressure vessel. The pressure vessel is evacuated through a snorkel fluidically connected to the mold chamber and extending therefrom out of the pressure vessel. The material in the crucible is melted. The crucible is placed in fluidic communication with the mold chamber such that the melted material fluidically seals the inside of the mold chamber and the snorkel from the interior of the pressure vessel to fluidically isolate the mold chamber from the interior of the pressure vessel so that a pressure differential exists therebetween.

Abstract: The present invention is a process for forming net shape parts by matching mold and component CTE and having the mold heated near the liquidus such that the mold and the component go through the same thermal and dimensional changes during cool down of the component. The present invention also pertains to a method of producing the matched CTE mold. The method includes the step of providing the first material in porous form. Next, there is the step of melting the second material. Then, there is the step of infiltrating the first porous material with the second melted material in proportion such that their combined CTE essentially matches that of the composite component. The composite mold and composite component can be formed at the same time. In an alternative method for forming the mold having a specific CTE, there is the step of providing the first material and the second material.

Abstract: The present invention pertains to an apparatus for casting comprised of a pressure vessel and means for evacuating and pressurizing the vessel. The evacuating and pressurizing means is in fluidic connection with the vessel. The apparatus is also comprised of a crucible disposed in the pressure vessel within which material is melted. There is a mold disposed in the pressure vessel. Additionally, the apparatus is comprised of means for heating material in the crucible and the mold in the mold chamber such that material is melted in the crucible and stays melted as it is drawn up to the mold chamber while the evacuating and pressurizing means evacuates the vessel, and when it is forced into the mold while the evacuating and pressurizing means charges the vessel. The heating means is disposed in the vessel. The pressurizing means comprises at least one chill line which serves to chill the mold as the vessel is pressurized. The present invention also pertains to a method for casting.

Abstract: A method for producing composite materials by forming one material in a die cavity such that another material can be forced into the same die cavity and infiltrate the spaces in the first material. A method for producing a composite comprising the steps of injecting reinforcement material in a binder or suspension into a die cavity; burning off or removing the binder or suspension such that the reinforcement material remains in the die cavity; injecting liquid metal into the same die cavity such that it infiltrates the reinforcement material; solidifying the liquid metal; and removing the metal infiltrated composite material from the die cavity. An apparatus comprised of a die and a die cavity disposed inside the die. The apparatus is also comprised of a first port extending from the die cavity to the surface of the die through which reinforcement material in a binder is injected into a die cavity.

Abstract: The present invention pertains to a warning apparatus with respect to a small sailing craft having a structure for holding a sail. The invention is comprised of a device for signaling that does not require the craft to be seen in order for a signal provided by the signaling device to be noticed. The signaling device is attached to the structure. Additionally, there is a device for activating the signaling device so a signal is produced thereby, the activating device is in communication with the signaling device. In a preferred embodiment, the activating device includes a powering device connected to the signaling device; and a device for actuating the powering device so the signaling device receives power to produce the signal.

Abstract: A method for forming a metal matrix composite within a mold of investment material. The method comprises the steps of forming a preform mixture of liquid flow medium, binding agent and reinforcement into the desired shape of a metal matrix composite. Then, allowing the preform mixture to solidify into desired shape. Next, encasing the preform mixture within investment material. Then, heating the preform mixture at a controlled rate which first allows any fluid, such as water, to evaporate, then allows removal of the flow medium. Next, sintering the remaining reinforcement material and binder to form a solid preform. Then, forcing molten metal under pressure into said preform. Next, solidifying the molten metal to form a metal matrix composite in the shape of this preform; and removing the investment material from metal matrix composite. Additionally, there is a method comprising the steps of connecting a preform, which has been previously prepared for infiltration of molten metal, to a sprue system.

Abstract: A porous preform is placed within a permanent, nonporous, thin walled mold chamber. The mold chamber is disposed within a pressure vessel. A material is placed in a crucible of the pressure vessel. The pressure vessel is evacuated through a snorkel fluidically connected to the mold chamber. There is means for cooling the snorkel in thermal communication with the snorkel. The material is melted within the crucible. The crucible is placed in fluidic communication with the mold chamber such that the melted material seals the inside of the mold chamber from the pressure vessel to isolate a vacuum within the mold chamber.

Abstract: The apparatus for casting comprises a pressure vessel and a device for evacuating and pressurizing the vessel. The evacuating and pressurizing device is in fluidic connection with the vessel. The apparatus is also comprised of a chamber disposed in the pressure vessel within which material is melted. There is a mold with a passage such that the melted material in the chamber can be forced down into the mold through the passage as the pressurizing device pressurize the vessel. The passage contains a filter such that the melted material is prevented from entering the interior of the mold prior to pressurization. Additionally, the apparatus is comprised of a device for heating material in the chamber and the mold such that material is melted in the chamber and stays melted as it is forced down into mold while the pressurizing device pressurizes the vessel. The heating device is disposed in the vessel.

Abstract: The present invention pertains to a warning apparatus with respect to a ski-pole. The warning apparatus is comprised of a device for signaling that does not require the ski-pole to be seen in order for a signal provided by the signaling device to be noticed. The signaling device is in juxtaposition with the ski-pole. Additionally, the warning apparatus is comprised of a device for activating the signaling device. The activating device is in communication with the signaling device. In a preferred embodiment, the activating device includes a device for powering the signaling device and a device for actuating the powering device so the signaling device receives power to produce a signal.

Abstract: The present invention pertains to a warning apparatus with respect to a bicycle. The warning apparatus is comprised of a device for signaling that does not require the bicycle to be seen in order for a signal provided by the signaling device to be noticed. The signaling device is in juxtaposition with the bicycle. Additionally, the warning apparatus is comprised of a device for activating the signaling device. The activating device is in communication with the signaling device. In a preferred embodiment, the activating device includes a device for powering the signaling device and a device for actuating the powering device so the signaling device receives power to produce a signal.