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THE LOST FOAM THE LOST FOAM CASTING PROCESSCASTING PROCESS

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THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESSProcess StepsProcess Steps

1.1. Mold foam pattern sections.Mold foam pattern sections.

2.2. Age pattern to allow dimensional shrinkage.Age pattern to allow dimensional shrinkage.

3.3. Assemble pattern if it is a multiple piece pattern.Assemble pattern if it is a multiple piece pattern.

4.4. Build cluster (multiple patterns per cluster).Build cluster (multiple patterns per cluster).

5.5. Coat cluster.Coat cluster.

6.6. Dry coating.Dry coating.

7.7. Compact cluster in flask.Compact cluster in flask.

8.8. Pour metal.Pour metal.

9.9. Extract cluster from flask.Extract cluster from flask.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS1. Mold Foam Pattern Sections1. Mold Foam Pattern Sections


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS2. Age Patterns2. Age Patterns

•• The foam material used to create the pattern The foam material used to create the pattern shrinks in much the same manner as a typical shrinks in much the same manner as a typical casting.casting.

•• Patterns are “aged” by allowing them to rest at Patterns are “aged” by allowing them to rest at room temperature for a period of 5 to 7 days.room temperature for a period of 5 to 7 days.

•• Patterns may also be force aged in a drying oven Patterns may also be force aged in a drying oven to allow for quicker use.to allow for quicker use.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS3. Assemble the Pattern3. Assemble the Pattern

•• Production patterns are Production patterns are assembled using a assembled using a precision, automated precision, automated gluing machine.gluing machine.

•• Glue is printed to one Glue is printed to one section of the foam and section of the foam and then pressed against the then pressed against the adjoining piece.adjoining piece.

•• Multiple piece parts can Multiple piece parts can be built up in this way be built up in this way and produce very and produce very complex geometrycomplex geometry


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS4. Clustering4. Clustering

•• Glue individual patterns Glue individual patterns to sprue.to sprue.

•• Number of patterns per Number of patterns per sprue is dependent on sprue is dependent on part size and/or part size and/or configuration.configuration.

•• Molded sprue is Molded sprue is manufactured similar to manufactured similar to foam patternfoam pattern


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS5. Coating5. Coating

•• Coating parameters are Coating parameters are verified before coating verified before coating cluster.cluster.

•• Coating is mixed Coating is mixed continuously to maintain continuously to maintain properties.properties.

•• Cluster may be hand Cluster may be hand dipped or by automated dipped or by automated robot station.robot station.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS6. Drying6. Drying

•• Coating is dried in an Coating is dried in an oven at 120oven at 120--140°F(49140°F(49--60°60°C)C) for 3 to 5 hours.for 3 to 5 hours.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS7. Compaction7. Compaction

•• Cluster is delivered to Cluster is delivered to the pouring line by the pouring line by conveyor.conveyor.

•• Cluster is placed into Cluster is placed into flask and held in position flask and held in position by a fixture by a fixture

•• Fixture is timed to Fixture is timed to release the cluster during release the cluster during the compaction cycle.the compaction cycle.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS7. Compaction (Cont.)7. Compaction (Cont.)

•• Sand is rained into flask Sand is rained into flask from overhead bin.from overhead bin.

•• Compaction tables can be Compaction tables can be either vertical or horizontal either vertical or horizontal in orientation and vibrate in orientation and vibrate the flask during filling.the flask during filling.

•• Sand is compacted from Sand is compacted from approximately 90lb/ft³ to approximately 90lb/ft³ to 100 lb/ft³ by the 100 lb/ft³ by the compaction table.compaction table.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS8. Metal Pour8. Metal Pour

•• Metal is poured to Metal is poured to displace the polystyrene displace the polystyrene pattern.pattern.

•• Metal may be poured by Metal may be poured by hand or with an hand or with an automatic ladle.automatic ladle.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS9. Extraction9. Extraction

•• Casting is allowed to Casting is allowed to cool in sand for a cool in sand for a predetermined period.predetermined period.

•• Flask is then dumped Flask is then dumped on to a shakeout on to a shakeout conveyor.conveyor.

•• Loose sand around the Loose sand around the casting cluster helps casting cluster helps protect the parts from protect the parts from damage.damage.


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESS9. Extraction (Cont.)9. Extraction (Cont.)

•• Castings proceed through Castings proceed through shakeout to remove loose shakeout to remove loose sand and coatingsand and coating


THE LOST FOAM CASTING PROCESSTHE LOST FOAM CASTING PROCESSFinal CastingFinal Casting


the lost foam casting process - austin group,...

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