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Lost foam cast process

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Credits: http://www.lostfoam.com

Credits: http://www.lostfoam.com

Published in: Education, Business, Technology
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  • 1. THE LOST FOAM CASTING PROCESSCopyright 2003 © Austin Group, LLC. All rights reserved.
  • 2. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 3. THE LOST FOAM CASTING PROCESS 1. Mold Foam Pattern SectionsCopyright 2003 © Austin Group, LLC. All rights reserved.
  • 4. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 5. THE LOST FOAM CASTING PROCESS 2. Age Patterns • The foam material used to create the pattern shrinks in much the same manner as a typical casting. • Patterns are “aged” by allowing them to rest at room temperature for a period of 5 to 7 days. • Patterns may also be force aged in a drying oven to allow for quicker use.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 6. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 7. THE LOST FOAM CASTING PROCESS 3. Assemble the Pattern • Production patterns are assembled using a precision, automated gluing machine. • Glue is printed to one section of the foam and then pressed against the adjoining piece. • Multiple piece parts can be built up in this way and produce very complex geometryCopyright 2003 © Austin Group, LLC. All rights reserved.
  • 8. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 9. THE LOST FOAM CASTING PROCESS 4. Clustering • Glue individual patterns to sprue. • Number of patterns per sprue is dependent on part size and/or configuration. • Molded sprue is manufactured similar to foam patternCopyright 2003 © Austin Group, LLC. All rights reserved.
  • 10. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 11. THE LOST FOAM CASTING PROCESS 5. Coating • Coating parameters are verified before coating cluster. • Coating is mixed continuously to maintain properties. • Cluster may be hand dipped or by automated robot station.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 12. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 13. THE LOST FOAM CASTING PROCESS 6. Drying • Coating is dried in an oven at 120-140°F(49- 60°C) for 3 to 5 hours.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 14. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 15. THE LOST FOAM CASTING PROCESS 7. Compaction • Cluster is delivered to the pouring line by conveyor. • Cluster is placed into flask and held in position by a fixture • Fixture is timed to release the cluster during the compaction cycle.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 16. THE LOST FOAM CASTING PROCESS 7. Compaction (Cont.) • Sand is rained into flask from overhead bin. • Compaction tables can be either vertical or horizontal in orientation and vibrate the flask during filling. • Sand is compacted from approximately 90lb/ft³ to 100 lb/ft³ by the compaction table.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 17. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 18. THE LOST FOAM CASTING PROCESS 8. Metal Pour • Metal is poured to displace the polystyrene pattern. • Metal may be poured by hand or with an automatic ladle.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 19. THE LOST FOAM CASTING PROCESS Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Compact cluster in flask. 8. Pour metal. 9. Extract cluster from flask.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 20. THE LOST FOAM CASTING PROCESS 9. Extraction • Casting is allowed to cool in sand for a predetermined period. • Flask is then dumped on to a shakeout conveyor. • Loose sand around the casting cluster helps protect the parts from damage.Copyright 2003 © Austin Group, LLC. All rights reserved.
  • 21. THE LOST FOAM CASTING PROCESS 9. Extraction (Cont.) • Castings proceed through shakeout to remove loose sand and coatingCopyright 2003 © Austin Group, LLC. All rights reserved.
  • 22. THE LOST FOAM CASTING PROCESS Final CastingCopyright 2003 © Austin Group, LLC. All rights reserved.

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