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Lost Foam Casting- Most Economic Casting Method

Feature

 

1. The lost foam technique is often cheaper than other casting methods in that a foam pattern can be fabricated much more easily than a die or mold and foam is cheaper than wax used in common investment casting. Lost foam casting has the additional benefit of producing an excellent surface finish further reducing production costs.

2. Additionally, the mold used to fabricate the EPS foam casting mold is not subjected to the extreme conditions of direct molding and will therefore produce a greater number of identical foam mold patterns to assure consistent quality of cast parts reducing re-tooling costs.

3. The workability of EPS foam invites the casting of custom single unit parts. The fabricator simply shapes the desired part in easy to work EPS foam rather than enduring the time and expense of creating a die mold or machining a part from billet or stock material.

The Casting Process1. A pattern is made from expanded polystyrene foam.  The final pattern is approximately 97.5% air 2.5% polystyrene.2. The foam is coated with ceramic investment, also known as refractory coating, by dipping, brushing, spraying or flow coating.  The coating creates a barrier between the smooth foam surface and the coarse sand surface.  The coating also controls permeability, which allows the gas created by the vaporized foam pattern to escape through the coating into the sand. The coating foams a barrier so that the molten metal does not penetrate of cause sand erosion during pouring.  3. After the coating dries, the cluster is placed into a flask and backed up with un-bonded sand.  The sand is then compacted using a vibration table.  Once compacted the mold is ready to be poured.4. Molten metal is then poured into the EPS pattern, which vaporizes and is replaced by metal.  Vents in the side of the flask allow vapor to escape.5. The ceramic investment is then removed, revealing the metal part 

Lost Foam Casting- Most Economic Casting Method