Lost Foam Casting Parts

Material: Gray Iron, Ductile Iron, Steel
Process: Lost Foam Cast + Machining
Weight: 8 kg
Application: Gearbox Housing

Lost foam casting parts as per customized requirements and engineering services.

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Description

Lost foam casting parts as per customized requirements and engineering services

Lost Foam Casting, also known as Full Mold Casting, or Cavityless Molding Casting, refers to a casting method that combines foam molding with dry sand molding. The molten metal directly fills and replaces the space occupied by the original plastic mold, and directly obtains the required casting after cooling. The foam pattern is directly vaporized during the metal casting process, so the lost foam casting does not require mold removal. During the lost foam casting process, the lost foam casting foundry usually the polystyrene as the pattern materials.

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

lost foam casting foundry

▶ Raw Materials Available for Lost Foam Casting (LFC)

Carbon Steel: Low carbon, medium carbon and high carbon steel from AISI 1020 to AISI 1060.
Cast 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.
Grey Cast Iron, Ductile Cast Iron
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.

▶ Main Steps of Lost Foam Casting
During lost foam casting process, the sand is not bonded and a foam pattern is used to form the shape of the desired metal parts. The foam pattern is "invested" into the sand at the Fill & Compact process station allowing the sand into all voids and supporting the foam patterns external form. The sand is introduced into the flask containing the casting cluster and compacted to ensure all voids and sapes are supported.

Mold foam pattern making.
Age pattern to allow dimensional shrinkage.
Assemble pattern into a tree
Build cluster (multiple patterns per cluster).
Coat cluster.
Foam pattern coating.
Compact cluster in flask.
Pour molten metal.
Extract cluster from flasks.

▶ How We Inspect 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

▶ 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.
Machining: Turning, Milling, Lathing, Drilling, Honing, Grinding.

▶ Why You Choose RMC for Custom Lost Foam Casting Parts?

Greater design freedom in the construction of cast parts
Small quantity is possible due to the layered structure of the pattern.
Lower need for secondary machining with near net shape.
High flexibility by short start up lead time.
Longer EPS mould span life, thus lower average tool costs

▶ 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.

Capabilities for Casting at RMC' Foundry
Casting Process		Annual Capacity / Tons	Main Metals	Casting Weights	Dimensional Tolerance Grade of Castings (ISO 8062)	Heat Treatment
Green Sand Casting		6000	Cast Gray Iron, Cast Ductile Iron, Cast Aluminium, Brass, Cast Steel, Stainless Steel	0.3 kg to 200 kg	CT11~CT14	Normalization, Quenching, Tempering, Annealing, Carburization
Shell Mold Casting				0.66 lbs to 440 lbs	CT8~CT12
Lost Wax Investment Casting	Water Glass Casting	3000	Stainless Steel, Carbon Steel, Steel Alloys, Brass, Cast Aluminium, Duplex Stainless Steel	0.1 kg to 50 kg	CT5~CT9
				0.22 lbs to 110 lbs
	Silica Sol Casting	1000		0.05 kg to 50 kg	CT4~CT6
				0.11 lbs to 110 lbs
Lost Foam Casting		4000	Gray Iron, Ductile Iron, Steel Alloys, Carbon Steel, Stainless Steel	10 kg to 300 kg	CT8~CT12
				22 lbs to 660 lbs
Vacuum Casting		3000	Gray Iron, Ductile Iron, Steel Alloys, Carbon Steel, Stainless Steel	10 kg to 300 kg	CT8~CT12
				22 lbs to 660 lbs
High Pressure Die Casting		500	Aluminium Alloys, Zinc Alloys	0.1 kg to 50 kg	CT4~CT7
				0.22 lbs to 110 lbs