Lost Foam Casting Company

Lost Foam Casting Company

Material: Gray Iron, Ductile Iron, Cast Steel
Process: Lost Foam Casting + Machining
Weight: 8.70 kg
Application: Heavy Truck

China Lost Foam Casting Company with OEM Customized Services.

Description

Lost Foam Casting Company with OEM Customized Services.

Lost Foam Casting vs Vacuum Casting

Item Lost Foam Casting Vacuum Casting
Suitable Castings Small and medium-sized castings with complex cavities, such as engine block, engine cover Medium and large castings with few or no cavities, such as cast iron counterweights, cast steel axle housings
Patterns and Plates Foam patterns made by moldings Template with suction box
Sand Box Bottom or five sides exhaust Four sides exhaust or with exhaust pipe
Plastic Film The top cover is sealed by plastic films All sides of both halves of sand box are sealed by plastic films
Coating Materials Water-based paint with thick coating Alcohol-based paint with thin coating
Molding Sand Coarse dry sand Fine dry sand
Vibration Molding 3 D Vibration Vertical or Horizontal Vibration
Pouring Negative Pouring Negative Pouring
Sand Process Relieve negative pressure, turn over the box to drop sand, and the sand is then reused Relieve negative pressure, then the dry sand falls into the screen, and the sand is recycled

▶ Ferrous and Non-Ferrous Metals for Lost Foam Casting (LFC):


  • Cast Iron: Ductile Iron, Gray Iron, White Iron, Malleable Iron.
  • Carbon Steel: AISI 1020 - AISI 1060
  • Steel Alloys: ZG20SiMn, ZG30SiMn, ZG30CrMo, ZG35CrMo, ZG35SiMn, ZG35CrMnSi, ZG40Mn, ZG40Cr, ZG42Cr, ZG42CrMo...etc on request.
  • Stainless Steel: AISI 304, AISI 304L, AISI 316, AISI 316L and other stainless steel grade.
  • Brass & Copper.
  • Other Materials and Standards on request

▶ Capabilities of Lost Foam Casting
  • Max Size: 1,000 mm × 800 mm × 500 mm
  • Weight Range: 0.5 kg - 100 kg
  • Annual Capacity: 2,000 tons
  • Tolerances: On Request.

▶ Inspecting Lost Foam Castings
  • Spectrographic and manual quantitative analysis
  • Metallographic analysis
  • Brinell, Rockwell and Vickers hardness inspection
  • Mechanical property analysis
  • Low and normal temperature impact testing
  • Cleanliness inspection
  • UT, MT and RT inspection

The general lost foam casting process are as in the following:
  • Use foam molds to produce foam patterns and casting gating systems
  • Bond the patterns and runners to form a mold bundle module
  • Dip paint on the module with refractory materials
  • Dry the paint
  • Put the module into the sand box and fill it with dry sand
  • Vibrate molding in order to fill the cavity with dry sand and then compact the molding sand
  • Pouring molten metal to vaporize the foam and then forming the desired castings
  • After the castings have cooled, clean the castings. The dry sand can be recycled

▶ Post-Casting Process
  • Deburring & Cleaning
  • Shot Blasting / Sand Peening
  • Heat Treatment: Normalization, Quench, Tempering, Carburization, Nitriding
  • Surface Treatment: Passivation, Andonizing, Electroplating, Hot Zinc Plating, Zinc Plating, Nickel Plating, Polishing, Electro-Polishing, Painting, GeoMet, Zintec.
  • CNC Machining: Turning, Milling, Lathing, Drilling, Honing, Grinding.

▶ Why You Choose RMC for Custom Lost Foam Casting Parts?
  • Full solution from one single supplier ranging customized pattern design to finished castings and secondary process including machining, heat treatment and surface treatment.
  • Costdown proposals from our professional engineers based on your unique requirement.
  • Short leadtime for prototype, trial casting and any possible technical improvement.
  • Bonded Materials: Silica Col, Water Glass and their mixtures.
  • Manufacturing flexibility for small orders to mass orders.
  • Strong outsourcing manufacturing capabilities.

▶ General Commerial Terms
  • Main workflow: Inquiry & Quotation → Confirming Details / Cost Reduction Proposals → Tooling Development → Trial Casting → Samples Approval → Trial Order → Mass Production → Continuous Order Proceeding
  • Leadtime: Estimatedly 15-25 days for tooling development and estimatedly 20 days for mass production.
  • Payment Terms: To be negotiated.
  • Payment methods: T/T, L/C, West Union, Paypal.