Lost Foam Process Steps

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Description of steps in Industrial Lost foam casting process. Presentation

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Lost Foam Process Steps

  1. 1. LOST FOAMPROCESS CHAIN
  2. 2. Raw material with blowing agentPreexpansion Steam heat appliedMoulding EPS expanded factor ca. 30 Density control criticalStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  3. 3. EPS beads filled into Al toolPreexpansion Steam heated to expand and fuseMoulding Cooled to avoid distorsion Automatic removalStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  4. 4. Controlled shrinkagePreexpansion Accelerated processingMoulding Repeatability 0,2Stabilisation 0,1 0Glueing -0,1 0 100 200 300 400Coating -0,2 With Stabilisation Oven -0,3 Without Stabilisation OvenDrying -0,4 -0,5Cluster Insertion time (mins)Sand FillCompactionMetal PouringExtraction
  5. 5. Preexpansion Hot melt glueMoulding Short “open time” RepeatabilityStabilisation AccuracyGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  6. 6. PreexpansionMoulding Coating developed for lost foam RepeatabilityStabilisation Ceramic slurryGlueing Precise viscosity/solidsCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  7. 7. PreexpansionMoulding Removal of all moisture Temperature/humidity controlledStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  8. 8. PreexpansionMouldingStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  9. 9. Preexpansion Dry unbonded sandMoulding Rain-fillStabilisation Uniform Rate controllableGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  10. 10. PreexpansionMouldingStabilisationGlueingCoatingDryingCluster InsertionSand Fill Vibration Analysis 5,0 5 FFT Analysis 4Compaction 2,5 3 0,0 2Metal Pouring -2,5 1 0 -5,0 -1Extraction 0 25 50 75 100 0 25 50 75 100 ms Hz
  11. 11. EPS liquified and volatisedPreexpansion Metal replaces foamMoulding All details reproducedStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  12. 12. No shakeoutPreexpansion Sand dry and looseMoulding Sand easily recycledStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  13. 13. VULCAN ENGINEERING´SEXPERIENCE & EXPERTISE WAS INSTRUMENTAL TO SUCCESS OF MOST OPERATING LOST FOAM FOUNDRIES TODAY.

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