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 bearing housing, or integrated turbocharger housing, with the oil, and optionally air and water galleries, included as as-cast features, thereby avoiding the problems, design limitations and expense associated with conventional post-casting machining. The method of casting preferably uses lost foam casting, or a technique similar to lost foam casting but in which a ceramic shell is formed on the foam form prior to metal casting, but can use any of a variety of casting techniques or a combination of two or more techniques.

Lost wax casting bonding methods and systems. A method for bonding a wax component in a feeder system for a lost wax casting process comprises embedding conductive nano-particles in wax to form a sacrificial susceptor. The method includes coupling the wax component to another component such that the sacrificial susceptor is at an interface of the wax component and the other component. The method comprises inductively heating the sacrificial susceptor to cause the wax of the sacrificial susceptor and at least a portion of wax of the wax component to melt to thereby form a bond between the wax component and the other component.

A field of lost pattern casting, and more particularly to a casting tree for lost pattern casting, and also to its method of assembly is provided. The casting tree includes at least one part support, at least one pattern, and at least one first male-female connection connecting the pattern to the part support. The first male-female connection includes an orifice, a peg at least partially inserted inside the orifice, and a film of meltable material interposed at least between an outside surface of the peg and an inside surface of the orifice.

A method of freeze-drying comprising rapidly freezing either liquid or supercritical carbon dioxide in and around a material having pores at a rate of at least 0.2 C./min to limit the size of crystals formed from the carbon dioxide so as to avoid the formation of gas bubbles and damage to the pores and exposure of the material to gas-liquid interfaces. During freezing a solid layer primarily of solid carbon dioxide is formed on and surrounding the material by transferring heat with a cryogenic liquid circulating about the material. This solid layer protects the material from gas-liquid interfaces and surface tension before decreasing pressure about the material by venting carbon dioxide.

An apparatus for wax welding is provided that includes a removable cartridge adapted for operative engagement with a power supply. The removable cartridge includes a tube defining a proximal end portion, a distal end portion, a longitudinal axis, and a hollow bore, and a self-regulating heater is disposed within the tube. The apparatus further includes a tip secured to the distal end portion of the tube within the hollow bore, the tip defining a proximal end portion having an internal cavity. The tip defines an upper surface, a lower surface, and the tip is oriented relative to a longitudinal axis of the cartridge.

A dental restoration model including a positive model (15) of a dental restoration piece. The positive model (15) defines at least the outer contour (36) of a dental restoration piece to be made using lost wax technology and is provided with a locating pin region which is defined especially according to a given optimization process. The locating pin region is provided with a guiding element (30) which accommodates and/or guides a material feeder (22, 24, 26 and 28).

A field of lost pattern casting, and more particularly to a casting tree for lost pattern casting, and also to its method of assembly is provided. The casting tree includes at least one part support, at least one pattern, and at least one first male-female connection connecting the pattern to the part support. The first male-female connection includes an orifice, a peg at least partially inserted inside the orifice, and a film of meltable material interposed at least between an outside surface of the peg and an inside surface of the orifice.

A wax mold for investment casting includes a sprue having at least one pattern support. The pattern support includes a plurality of sockets formed therein. The wax mold further includes a plurality of wax patterns. Each wax pattern has a portion received in a respective one of the plurality of sockets to support the wax patterns on the at least one pattern support.

A fabrication method for fabricating a pattern for lost pattern casting, comprising at least one insert (10), providing at least two pattern portions (12, 14), said at least two portions being made of a material that can be eliminated, and assembling said at least two pattern portions together around at least a portion of said at least one insert in sealed manner so as to make said pattern (16).