Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.

Abstract: A method of producing an investment casting ceramic core is provided that includes: providing a core body consisting of a leachable material; surrounding the core body with a mold composition within a vessel, which mold composition is configured to solidify; leaching the core body from the mold composition subsequent to the mold composition solidifying, thereby leaving an internal cavity within the solidified mold composition; depositing a ceramic composition within the internal cavity of the solidified mold composition; sintering the ceramic composition to a solid ceramic core; and removing the solid ceramic core from the mold composition.

Abstract: In a method for removing a carbon-containing pattern material from a casting shell, a first step evaporates and pyrolizes the pattern material to leave carbon and a second step oxidizes the carbon.

Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.

Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate.

Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.

Abstract: A method of manufacturing includes providing a casting assembly, providing a material having solid, transition, and liquid phases, heating the material to form the liquid phase, supplying the material to the casting assembly, cooling the material, monitoring the solidification of the material from the liquid phase through the transition phase, and moving one of the casting mold or the reusable core in a first direction relative to the other when a substantial portion of the reusable core contacts the transition phase. The casting assembly comprises a casting mold and a reusable core inserted within the casting mold.

Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.