Lost Foam Casting Steps - English

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Lost Foam Casting Steps Presentation by Karel Cermak - Cermak Engineering (English Version)

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LOST FOAM
PROCESS CHAIN

Raw material with blowing agent
Preexpansion Steam heat applied
Moulding EPS expanded factor ca. 30
Density control critical
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

EPS beads filled into Al tool
Preexpansion Steam heated to expand and fuse
Moulding Cooled to avoid distorsion
Automatic removal
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

Controlled shrinkage
Preexpansion Accelerated processing
Moulding Repeatability
0,2

Stabilisation 0,1

0
Glueing -0,1
0 100 200 300 400

Coating -0,2
With Stabilisation Oven
-0,3 Without Stabilisation Oven
Drying -0,4

-0,5

Cluster Insertion time (mins)

Sand Fill
Compaction
Metal Pouring
Extraction

Preexpansion
Hot melt glue
Moulding Short “open time”
Repeatability
Stabilisation Accuracy
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

Preexpansion
Moulding Coating developed for lost foam
Repeatability
Stabilisation Ceramic slurry
Glueing Precise viscosity/solids

Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

Preexpansion
Moulding Removal of all moisture
Temperature/humidity controlled
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

Preexpansion
Dry unbonded sand
Moulding Rain-fill
Stabilisation Uniform
Rate controllable
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

Preexpansion
Moulding
Stabilisation
Glueing
Coating
Fluidisation - Compaction
Drying Precise control
Cluster Insertion
Sand Fill Vibration Analysis
5,0 5
FFT Analysis
4

Compaction 2,5
3

0,0 2

Metal Pouring -2,5
1

0

-5,0 -1

Extraction
0 25 50 75 100 0 25 50 75 100
ms Hz

EPS liquified and volatised
Preexpansion Metal replaces foam
Moulding All details reproduced

Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

No shakeout
Preexpansion Sand dry and loose
Moulding Sand easily recycled

Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

VULCAN ENGINEERING´S
EXPERIENCE & EXPERTISE
WAS INSTRUMENTAL TO
SUCCESS OF MOST
OPERATING LOST FOAM
FOUNDRIES TODAY.

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Lost Foam Casting Steps - English

1. LOST FOAM PROCESS CHAIN

2. Raw material with blowing agent Preexpansion Steam heat applied Moulding EPS expanded factor ca. 30 Density control critical Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

3. EPS beads filled into Al tool Preexpansion Steam heated to expand and fuse Moulding Cooled to avoid distorsion Automatic removal Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

4. Controlled shrinkage Preexpansion Accelerated processing Moulding Repeatability 0,2 Stabilisation 0,1 0 Glueing -0,1 0 100 200 300 400 Coating -0,2 With Stabilisation Oven -0,3 Without Stabilisation Oven Drying -0,4 -0,5 Cluster Insertion time (mins) Sand Fill Compaction Metal Pouring Extraction

5. Preexpansion Hot melt glue Moulding Short “open time” Repeatability Stabilisation Accuracy Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

6. Preexpansion Moulding Coating developed for lost foam Repeatability Stabilisation Ceramic slurry Glueing Precise viscosity/solids Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

7. Preexpansion Moulding Removal of all moisture Temperature/humidity controlled Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

8. Preexpansion Moulding Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

9. Preexpansion Dry unbonded sand Moulding Rain-fill Stabilisation Uniform Rate controllable Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

10. Preexpansion Moulding Stabilisation Glueing Coating Fluidisation - Compaction Drying Precise control Cluster Insertion Sand Fill Vibration Analysis 5,0 5 FFT Analysis 4 Compaction 2,5 3 0,0 2 Metal Pouring -2,5 1 0 -5,0 -1 Extraction 0 25 50 75 100 0 25 50 75 100 ms Hz

11. EPS liquified and volatised Preexpansion Metal replaces foam Moulding All details reproduced Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

12. No shakeout Preexpansion Sand dry and loose Moulding Sand easily recycled Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction

13. VULCAN ENGINEERING´S EXPERIENCE & EXPERTISE WAS INSTRUMENTAL TO SUCCESS OF MOST OPERATING LOST FOAM FOUNDRIES TODAY.