lost foam process steps

LOST FOAM LOST FOAM PROCESS CHAINPROCESS CHAIN

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Raw material with blowing agentSteam heat appliedEPS expanded factor ca. 30Density control critical

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

EPS beads filled into Al toolSteam heated to expand and fuseCooled to avoid distorsionAutomatic removal

-0,5

-0,4

-0,3

-0,2

-0,1

0

0,1

0,2

0 100 200 300 400

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Controlled shrinkageAccelerated processingRepeatability

time (mins)

With Stabilisation OvenWithout Stabilisation Oven

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Hot melt glueShort “open time”RepeatabilityAccuracy

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Coating developed for lost foamRepeatabilityCeramic slurryPrecise viscosity/solids

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Removal of all moistureTemperature/humidity controlled

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Dry unbonded sandRain-fillUniformRate controllable

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction ms0 25 50 75 100

5,0

2,5

0,0

-2,5

-5,0

Hz0 25 50 75 100

5

4

3

2

1

0

-1

Vibration Analysis FFT Analysis

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

EPS liquified and volatisedMetal replaces foamAll details reproduced

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

No shakeoutSand dry and looseSand easily recycled

VULCAN ENGINEERING´SEXPERIENCE & EXPERTISE

WAS INSTRUMENTAL TO SUCCESS OF MOST

OPERATING LOST FOAM FOUNDRIES TODAY.