A hollow spherical glass particle, comprising aluminum oxide Al.sub.2O.sub.3, silicon dioxide SiO.sub.2 and at least one metal oxide, wherein the metal oxide is selected from the group consisting of alkali metal oxides and alkaline earth metal oxides, wherein the ratio of aluminum atoms to alkali metal atoms is about 1:1 and the ratio of aluminum atoms to earth alkali atoms is about 2:1, with the proviso that the hollow spherical glass particle is free of boron.

A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

A multiphase composite, formed by freeze-casting, lyophilization, and sintering, has sintered particles forming a scaffold having at least one region of aligned porosity; and a second phase formed in pores of the scaffold. In a particular embodiment, the second phase is a nuclear fuel, in another, the first phase is a nuclear fuel, and in others, both phases are nuclear fuels. In some embodiments, the first phase is a ceramic, and in other embodiments a metal such as stainless steel. In other embodiments, the second phase is a metal, and in other embodiments a ceramic. In some embodiments the second phase is positioned in a subset of pores of the scaffold, at least some additional pores being filled with a third phase. In embodiments, the second phase is also sintered.

A method of producing a metal form containing dispersed aerogel particles impregnated with polymers comprising a method of impregnating an aerogel with polymers, placing the aerogel impregnated with polymers within a dissolved polymer, cooling the dissolved polymer to create a polymer form with dispersed aerogel particles impregnated with polymers, adding molten metal to the polymer form, vaporizing the polymer form, replacing the polymer form with molten metal, and cooling the molten metal to yield a metal form containing dispersed aerogel particles impregnated with polymers. Dispersing the aerogel particles impregnated with polymers within the polymer form prior to adding molten metal allows the aerogel particles to be fully dispersed throughout the metal form.

A multiphase composite, formed by freeze-casting, lyophilization, and sintering, has sintered particles forming a scaffold having at least one region of aligned porosity; and a second phase formed in pores of the scaffold. In a particular embodiment, the second phase is a nuclear fuel, in another, the first phase is a nuclear fuel, and in others, both phases are nuclear fuels. In some embodiments, the first phase is a ceramic, and in other embodiments a metal such as stainless steel. In other embodiments, the second phase is a metal, and in other embodiments a ceramic. In some embodiments the second phase is positioned in a subset of pores of the scaffold, at least some additional pores being filled with a third phase. In embodiments, the second phase is also sintered.

Provided are a brake disc and a brake disc manufacturing method. The brake disc manufacturing method may include a porous metal block preparation operation for preparing a porous metal block having a plurality of pores therein, and an insert casting operation for mounting the porous metal block in a mold and casting a disc plate material to manufacture a brake disc.

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.

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.

The present invention includes a method of producing a porous metal casting comprising: forming a salt preform structure in a 3D printed polymeric matrix comprising one or more openings in a heat resistant vessel; removing the 3D printed polymeric matrix by dissolving, melting, or sintering; adding, melting or casting one or more metals into the salt preform structure; and dissolving the salt preform structure to produce the porous metal casting.

A method for continuously producing a strip-shaped metallic workpiece may involve introducing a molten mass into a casting region, solidifying the molten mass introduced into the casting region at least partially, and conveying the at least partially solidified molten mass out of the casting region. Hollow bodies may be added to the molten mass and encapsulated into the workpiece. Further, an apparatus for continuously producing a strip-shaped metallic workpiece may include a casting region into which a molten mass can be introduced and in which the molten mass introduced can solidify at least partially. The apparatus may also include a conveying device for conveying the molten mass out of the casting region, as well as a metering apparatus for adding hollow bodies to the molten mass.