THE LOST FOAM CASTING PROCESS

LostLost-foam casting


LostLost-foam casting (LFC) is a type LFC) of evaporative-pattern casting process that is similar to investment casting except foam is used for the pattern instead of wax. This process takes advantage of the low boiling point of foam to simplify the investment casting process by removing the need to melt the wax out of the mold.

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

1. Mould Foam Pattern Sections

THE LOST FOAM CASTING PROCESS

Process Steps
        

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

2. Age Patterns


The foam material used to create the pattern shrinks in much the same manner as a typical casting. Patterns are aged by allowing them to rest at room temperature for a period of 5 to 7 days. Patterns may also be force aged in a drying oven to allow for quicker use.

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

3. Assemble the Pattern


Production patterns are assembled using a precision, automated gluing machine. Glue is printed to one section of the foam and then pressed against the adjoining piece. Multiple piece parts can be built up in this way and produce very complex geometry.

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

4. Clustering


Glue individual patterns to sprue. Number of patterns per sprue is dependent on part size and/or configuration. Moulded sprue is manufactured similar to foam pattern

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

5. Coating


Coating parameters are verified before coating cluster. Coating is mixed continuously to maintain properties. Cluster may be hand dipped or by automated robot station.

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

6. Drying

Coating is dried in an oven at 120-140F(49 -60 C) for 3 to 5 hours.

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

7. Compaction


Cluster is delivered to the pouring line by conveyor. Cluster is placed into flask and held in position by a fixture. Fixture is timed to release the cluster during the compaction cycle.

THE LOST FOAM CASTING PROCESS

7. Compaction (Contd.)


Sand is rained into flask from overhead bin. Compaction tables can be either vertical or horizontal in orientation and vibrate the flask during filling. Sand is compacted from approximately 90lb/ft to 100 lb/ft by the compaction table.

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

8. Metal Pour


Metal is poured to displace the polystyrene pattern. Metal may be poured by hand or with an automatic ladle.

THE LOST FOAM CASTING PROCESS

Process Steps
  

     

1. Mould foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.

THE LOST FOAM CASTING PROCESS

9. Extraction


Casting is allowed to cool in sand for a predetermined period. Flask is then dumped on to a shakeout conveyor. Loose sand around the casting cluster helps protect the parts from damage.

THE LOST FOAM CASTING PROCESS

9. Extraction (Contd.)


Castings proceed through shakeout to remove loose sand and coating.

THE LOST FOAM CASTING PROCESS

Final Casting

DETAILS


Commonly cast metals include cast irons, aluminium alloys, steels, and nickel alloys; less frequently stainless steels and copper alloys are also cast. The size range is from 0.5 kg (1.1 lb) to several tonnes (tons). The minimum wall thickness is 2.5 mm (0.098 in) and there is no upper limit. Typical surface finishes are from 2.5 to 25 m (100 to 1000 in) Typical linear tolerances are 0.005 mm/mm (0.005 in/in).

Advantages


This casting process is advantageous for very complex castings that would regularly require cores. It is also dimensionally accurate, maintains an excellent surface finish, requires no draft, and has no parting lines so no flash is formed. As compared to investment casting, it is cheaper because it is a simpler process and the foam is cheaper than the wax.

Advantages


Risers are not usually required due to the nature of the process; because the molten metal vaporizes the foam the first metal into the mold cools more quickly than the rest, which results in natural directional solidification. Foam is easy to manipulate, carve and glue, due to its unique properties.

Disadvantages


The main disadvantage is that pattern costs can be high for low volume applications. The patterns are easily damaged or distorted due to their low strength. If a die is used to create the patterns there is a large initial cost.

Timeline


LostLost-foam casting was invented in 1964 by M.C. Flemmings. Public recognition of the benefits of LFC was made by General Motors in the mid 1980s when it announced its new car Saturn, line, Saturn, would utilize LFC for production of all engine blocks, cylinder blocks, heads, crankshafts, heads, crankshafts, differential carriers, carriers, and transmission cases

Thank You
PAWAN KUMAR VERMA B.Tech 2nd Yr MEME-B R.No.R.No.- 0900140072 Anand Engg College, Agra