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Lost Foam Casting

Article source:未知 Popularity: Issuing time:2024-07-18
  • Lost Foam Casting is a near net shape and precision forming process; and it is regarded as the
    representative of the 21st century casting new technology
  • The Lost Foam castings have low surface roughness and high dimensional precision.
  • The Lost Foam Process, also called the evaporative pattern technology, offers new ecological and energy-saving technologies to the casting manufacturing process and may improve the energy efficiency of a foundry process by 27%.
  • In this technology, patterns are made from foamed polystyrene (EPS). Foaming of the polystyrene is carried out not only to make patterns of the required configurations but also to achieve the required density. Using proper glues, patterns are joined together to make a solid assembly,composed of several patterns with a gating system. The ready pattern assembly is coated with a layer of ceramic material. Pattern assemblies are molded, and moulds are compacted by vibrations. When the mould is poured with liquid metal, the latter is acting on the pattern and makes it
    evaporate
  • Foam cast process castings are generally more expensive than forged parts, or parts made by other casting processes. The value inherent in the foam cast process versus other processes is seen in tighter tolerances, weight reduction and as-cast features which all results in less machining and cleanup time. Many castings that require milling, turning, drilling and grinding can be made in the foam cast process with only 5-8mm of machine stock.
  • Generally, 500-1000 pieces per year is the minimum production run to be economical. Prototyping runs, however, may be as few as 3-5 pieces for Fabricated Foam patterns or 20-100 pieces for Quick-Cut CNC machined aluminum tooling.
  • Generally, 8 to 16 weeks is typical for completed tooling and first castings produced. After casting approval, 6 to 12 weeks is typical for production run start-up. Rapid prototyping methods can produce castings in as little as 2 to 3 weeks.
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