1. A method of forming a preformed insert for a cast part, the method comprising the steps of:
forming a ceramic slurry compound; and
immersing an open cell structure into the ceramic slurry compound for coating the open-celled structure to form the preformed insert.
2. The method of claim 1, wherein the preformed insert is configured as an annulus.
3. The method of claim 1, wherein the preformed insert is configured as a segment of an annulus.
4. The method of claim 1, wherein there is further provided the step of casting the cast part, said step of casting the cast part comprising the further steps of:
depositing the preformed insert into a mold; and
infiltrating the preformed insert with molten metal.
5. The method of claim 4, wherein prior to performing said step of infiltrating the preformed insert with molten metal, there is provided the further step of affixing the preformed insert within the mold.
6. The method of claim 4, wherein prior to performing said step of infiltrating the preformed insert with molten metal, there is provided the further step of locating the preformed insert within the mold to ensure that it is completely covered by the molten metal during said step of infiltrating the preformed insert with molten metal.
7. The method of claim 1, wherein there is further provided the step of reducing negative effects in an iron casting process or a metal-matrix composite product such as casting porosity or gas build-up inside the mold.
8. The method of claim 1, wherein there is further provided the step of manipulating and controlling the density and weight of a metal-matrix composite product.
9. The method of claim 1, wherein there is further provided the step of manipulating and controlling dampening characteristics of a metal-matrix composite product.
10. The method of claim 1, wherein the ceramic slurry compound comprises 50-90% Silicon Carbide; 10-50% Bentonite; 0-25% Silica.
11. The method of claim 1, wherein the ceramic slurry compound comprises 95-60% Silicon Carbide; 5-40% Calcium Aluminate.
12. The method of claim 1, wherein the ceramic slurry compound comprises 50-90% Silicon Carbide; 10-50% Fly Ash; 0-25% Silica.
13. The method of claim 1, wherein the ceramic slurry compound comprises 50-90% Silicon Carbide; 10-50% Rice Hull Ash; 0-25% Silica.
14. A cast wear element comprising:
a ceramic preformed insert having a predetermined configuration and porosity; and
a volume of metal arranged to infiltrate and substantially surround said ceramic preformed insert.
15. The cast wear element of claim 14, wherein said volume of metal is provided with a wear surface.
16. The cast wear element of claim 15, wherein said ceramic preformed insert is disposed at a predetermined distance from the wear surface.
17. The cast wear element of claim 14, wherein the cast wear element is a rotatory wear element, and said ceramic preformed insert is configured as an annulus.
18. The cast wear element of claim 14, wherein the cast wear element is a rotatory wear element, and said ceramic preformed insert is configured as an arcuate segment of an annulus.
19. A rotatory cast wear element comprising:
a ceramic preformed insert having a predetermined configuration and porosity, said ceramic preformed insert being formed of an open-celled structure coated with a ceramic slurry compound that has been sintered; and
a volume of cast iron arranged to infiltrate and substantially surround said ceramic preformed insert, said volume of cast iron having a wear surface.
20. The rotatory cast wear element of claim 19, wherein said ceramic preformed insert is disposed at a predetermined distance from the wear surface.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A manufacturing method of an optical film provided with a convexoconcave structure, comprises the steps of:
coating a resin solution including a first resin solved by a solvent onto an endless or roll-like mold provided with a convexoconcave structure, and forming a resin solution layer on the mold;
laminating a film substrate directly onto the resin solution layer to make a laminated film before the solvent in the resin solution layer is completely dried, the film substrate including a second resin, which absorbs the solvent or is soluble by the solvent; and
peeling the laminated film from the mold before the solvent in the laminated film is completely dried.
2. The manufacturing method of claim 1, wherein the first resin is substantially the same as the second resin.
3. The manufacturing method of claim 1, wherein the first resin is cellulose ester.
4. The manufacturing method of claim 1, wherein the second resin is cellulose ester.
5. The manufacturing method of claim 2, wherein the first resin and the second resin are cellulose ester.
6. The manufacturing method of claim 1, wherein the time from lamination of the film substrate onto the resin solution layer to the peeling of the laminated film is 30 seconds or less.