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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

  • 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
  • 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.