Lost Foam Casting
Lost foam casting is a type of evaporative pattern casting. This method is quite similar to investment casting which uses wax instead of foam in the pattern making process.
The foam pattern was first used in metalworking in 1958. Although this mold casting technique is not as popular as other methods such as sand mold casting or permanent casting, it maintains outstanding advantages, especially in casting complicated and precise molds.
For the production of castings with complex structure, Our Foundry has the lost foam casting system as well as several foam and gluing machines.
The lost foaming process is considered to be the most suitable casting process for the large scale metal parts with complex structure, weights from 0.5 kg to around 500 kg .
- Max Size of Lost Wax Castings: 1,000 mm x 800 mm x 500 mm
- Casting Weight Range: 0.5 kg -100 kg
- Annual Capacity: 1500 tons
- Casting Tolerances: according Clients request, if very strict tolerance, our in-house machining shop can reach
- Cast lron: Gray lron, Ductile lron (Nodular lron), Malleable lron
Aluminium and Aluminum alloy - Carbon Steel: Low carbon, medium carbon and high carbon steel from AlSl 1020 to AlSI 1060
- CastSteel:AllZG20SiMn,ZG30SiMn,ZG30CrMo,ZG35CrMo,ZG35SiMn,ZG35CrMnSi,ZG40Mn, ZG40CrZG42Cr. ZG42CrMo…etc on request.
- Stainless Steel: AlSl 304, AISI 304L, AIS| 316, AlSl 316L and other stainless steel grade Duplex Stainless Steel, Super Duplex Stainless Steel Brass, Bronze and other Copper-based Alloys.
- Wear-resistant Steel, Heat-resistant Steel, and Special Steel Alloys
1.Use Foam Molds for Foam Pattern and Gating System Production
In lost-foam casting, foam patterns mimic the precise geometry of the finished metal object. The gating system has passages that direct molten metal into the mold and may be integrated into the foam pattern or attached (glued on) later. These passages enable precise designs and streamlined metal flow, resulting in castings that are accurate and effective.
2.Bond Patterns and Runners to Create a Mold Bundle Module
Tightly bind the foam patterns and gating mechanisms to form the mold bundle module prior to casting. This assembly makes the casting process easier by ensuring precise component alignment, reducing mistakes, and facilitating reliable, consistent manufacture of complex metal parts.
3.Apply Dip Paint and Allow the Paint to Dry
An application of refractory dip paint follows the assembly of the mold bundle module. When this paint dries, it creates a protective ceramic coating that improves the mold’s surface toughness, heat resistance, and capacity to handle the temperature and pressure of the molten metal.
4.Place the Module in a Sandbox and Fill It with Dry Sand
Coat the mold bundle module, set it within a molding flask, and cover it in dry sand. This phase ensures accurate replication of the desired metal part by supporting the module’s shape, keeping it in place during casting, and facilitating uniform sand compaction.
5.Vibrate Molding to Fill the Cavity and Compact the Sand
Sand may now flow into every nook and cranny of the mold bundle module thanks to vibrations imparted to the molding flask. Through careful sand compaction and the elimination of air spaces, this procedure enables the creation of a high-quality casting with exact measurements and fine details.
6.Pour Molten Metal to Vaporize the Foam and Create Desired Castings
Carefully pour the molten metal into the mold, replacing the vaporized foam patterns. The metal solidifies to create the desired casting as it fills the spaces the foam left behind. As a result, the finished product closely resembles the planned form while minimizing flaws and blemishes. This technique supports complicated and complex shapes.
7.Clean the Castings After They Have Cooled
Siyuan foundry provides a comprehensive line of lost foam equipment, including flask pouring, flask handling and flask compaction. Our line of foam bead processing equipment is recognized world wide as the industry standard.Engineering team whose members are focusing on metal casting field.Extensive experience with complex geometries parts
- A broad range of materials, including ferrous and non-ferrous alloys
- In-house CNC machining capabilities
- One-stop solutions for castings and secondary process
- Consistent quality guaranteed and continuous improvement.
- Teamwork including toolmakers, engineers, foundry man, machinist and production technicians
