Chill Plate for Equiax Casting Solidification Control For Solid Mold Casting of Reticulated Metal Foams

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

1 . A method to manufacture reticulated metal foam, comprising:
 pre-investing a precursor with a pre-investment ceramic plaster to encapsulate the precursor;   investing the encapsulated precursor with a ceramic plaster to form a mold; and   pouring molten metal material into the mold while the mold is located on a chill plate.   
     
     
         2 . (canceled) 
     
     
         3 . The method as recited in  claim 1 , wherein the precursor is a reticulated foam structure. 
     
     
         4 . The method as recited in  claim 1 , wherein the precursor is a polyurethane reticulated foam structure. 
     
     
         5 . The method as recited in  claim 1 , wherein the precursor is completely encapsulated with the pre-investment ceramic plaster. 
     
     
         6 . The method as recited in  claim 1 , further comprising, coating the precursor in a molten wax to increase ligament thickness. 
     
     
         7 . 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. 
     
     
         8 . The method as recited in  claim 1 , wherein the ceramic plaster is more rigid than the pre-investment ceramic plaster. 
     
     
         9 . The method as recited in  claim 1 , wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio. 
     
     
         10 . The method as recited in  claim 1 , wherein the ceramic plaster is about 28:100 water to powder ratio. 
     
     
         11 . The method as recited in  claim 1 , wherein the chill plate operates at about room temperature. 
     
     
         12 . The method as recited in  claim 11 , wherein the molten metal material is at a temperature of about 1350° F. (732° C.). 
     
     
         13 . The method as recited in  claim 1 , wherein the chill plate applies an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end. 
     
     
         14 . The method as recited in  claim 1 , wherein the reticulated metal foam is manufactured of aluminum. 
     
     
         15 . A method to manufacture reticulated metal foam via a dual investment solid mold, comprising:
 investing an encapsulated precursor with a ceramic plaster to form a mold; and   pouring molten metal material into the mold while the mold is located on a chill plate.   
     
     
         16 . The method as recited in  claim 15 , wherein the precursor is a reticulated foam structure. 
     
     
         17 . The method as recited in  claim 16 , wherein the chill plate applies an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end. 
     
     
         18 . The method as recited in  claim 17 , wherein the extent of chilling is such that a casting formed by the mold remains equiaxial in nature with crystallization nucleating from all surfaces. 
     
     
         19 . A method to manufacture reticulated metal foam, comprising:
 locating a mold on a chill plate, the mold including a reticulated foam precursor that is pre-invested to form an encapsulated precursor, the encapsulated precursor invested with a ceramic plaster to form the mold.   
     
     
         20 . The method as recited in  claim 19 , wherein the extent of chilling is such that a casting formed by the molten metal material remains equiaxial with crystallization nucleating from all surfaces.