Lost Foam Process Steps
13
LOST FOAM LOST FOAM PROCESS CHAIN PROCESS CHAIN
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Description of steps in Industrial Lost foam casting process. Presentation
Transcript of Lost Foam Process Steps
LOST FOAM LOST FOAM PROCESS CHAINPROCESS CHAIN
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
Raw material with blowing agentSteam heat appliedEPS expanded factor ca. 30Density control critical
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
EPS beads filled into Al toolSteam heated to expand and fuseCooled to avoid distorsionAutomatic removal
-0,5
-0,4
-0,3
-0,2
-0,1
0
0,1
0,2
0 100 200 300 400
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
Controlled shrinkageAccelerated processingRepeatability
time (mins)
With Stabilisation OvenWithout Stabilisation Oven
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
Hot melt glueShort “open time”RepeatabilityAccuracy
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
Coating developed for lost foamRepeatabilityCeramic slurryPrecise viscosity/solids
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
Removal of all moistureTemperature/humidity controlled
Preexpansion
Moulding
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
Dry unbonded sandRain-fillUniformRate controllable
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction ms0 25 50 75 100
5,0
2,5
0,0
-2,5
-5,0
Hz0 25 50 75 100
5
4
3
2
1
0
-1
Vibration Analysis FFT Analysis
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
EPS liquified and volatisedMetal replaces foamAll details reproduced
Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction
No shakeoutSand dry and looseSand easily recycled
VULCAN ENGINEERING´SEXPERIENCE & EXPERTISE
WAS INSTRUMENTAL TO SUCCESS OF MOST
OPERATING LOST FOAM FOUNDRIES TODAY.
