초록

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then investing the encapsulated precursor with a ceramic plaster.

대표청구항 ▼

1. A method to manufacture reticulated metal foam via a dual investment solid mold, comprising: pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor, wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio; andinvesting

1. A method to manufacture reticulated metal foam via a dual investment solid mold, comprising: pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor, wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio; andinvesting the encapsulated precursor with a ceramic plaster. 2. The method as recited in claim 1, wherein the precursor is a reticulated foam. 3. The method as recited in claim 1, wherein the precursor is a polyurethane foam. 4. The method as recited in claim 1, wherein the precursor is completely encapsulated with the diluted pre-investment ceramic plaster. 5. The method as recited in claim 1, further comprising, coating the precursor in a molten wax to increase ligament thickness. 6. The method as recited in claim 1, further comprising, coating the precursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio. 7. The method as recited in claim 1, wherein the ceramic plaster is more rigid than the diluted pre-investment ceramic plaster. 8. The method as recited in claim 1, wherein the ceramic plaster is about 28:100 water to powder ratio. 9. A method to manufacture reticulated metal foam via a dual investment solid mold, comprising: coating a precursor in a molten wax to increase ligament thickness;pre-investing the waxed precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor, wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio; andinvesting the encapsulated precursor with a ceramic plaster. 10. The method as recited in claim 9, wherein the precursor is a reticulated foam. 11. The method as recited in claim 9, further comprising, coating the precursor in the molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio. 12. The method as recited in claim 9, wherein the ceramic plaster is more rigid than the diluted pre-investment ceramic plaster. 13. The method as recited in claim 9, wherein the ceramic plaster is about 28:100 water to powder ratio. 14. A dual investment solid mold, comprising: a precursor;a diluted pre-investment ceramic plaster over the precursor, wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio; anda ceramic plaster over the diluted pre-investment ceramic plaster. 15. The dual investment solid mold as recited in claim 14, wherein the precursor is reticulated foam. 16. The dual investment solid mold as recited in claim 14, further comprising, a molten wax over the precursor to increase ligament thickness to provide an about 90% air to 10% precursor ratio. 17. The dual investment solid mold as recited in claim 14, wherein the ceramic plaster is more rigid than the diluted pre-investment ceramic plaster. 18. The dual investment solid mold as recited in claim 14, wherein the ceramic plaster is about 28:100 water to powder ratio.