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, 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.

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

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.

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 method for producing an aluminum alloy foam wherein an aluminum alloy, in molten form, infiltrates the interstices of a preform of silicon elastomer elements, by means of a conventional molding process, typically a low-pressure process, followed by the elimination of the preform broken down into silica powder during the molding cycle and/or an additional baking cycle.

A device to be deployed downhole. The device includes a member including a metallic foam and a sealing material coupled to the metallic foam. The member attains a compressed shape when compressed to restrict fluid flow between regions downhole. The sealing material may be in, on or coated on the metallic foam member.

A method of producing a steel foam component includes providing a mold defining a cavity. The method also includes positioning an insert within the cavity of the mold. The insert can be configured to form a generally uniform pattern of pores within the steel foam component, and in some cases occupies at least 20% of the cavity. The method can further include pouring molten steel into the cavity, cooling the molten steel into the steel foam component, and removing the steel foam component and the insert from the mold. Steel components having internal shapes corresponding to the insert(s) are also provided.

A container for radioactive inventory has an end wall, a side wall, and a container lid that form a closed chamber for the radioactive inventory. A plastically deformable layer is provided between the container lid and the inventory and is of such a composition that, in the event of an impact of the inventory against the container lid, at least a majority of the impact forces are uniformly distributable over at least a majority of a surface of the plastically deformable layer.

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.