Project, Trade Technology Information - Contents on CD ROM

• Lost Foam Casting is a near net shape and precision forming process; and it is regarded as the
  representative of the 21st century casting new technology
• The Lost Foam castings have low surface roughness and high dimensional precision.
• The Lost Foam Process, also called the evaporative pattern technology, offers new ecological and energy-saving technologies to the casting manufacturing process and may improve the energy efficiency of a foundry process by 27%.
• In this technology, patterns are made from foamed polystyrene (EPS). Foaming of the polystyrene is carried out not only to make patterns of the required configurations but also to achieve the required density. Using proper glues, patterns are joined together to make a solid assembly,composed of several patterns with a gating system. The ready pattern assembly is coated with a layer of ceramic material. Pattern assemblies are molded, and moulds are compacted by vibrations. When the mould is poured with liquid metal, the latter is acting on the pattern and makes it
  evaporate
• Foam cast process castings are generally more expensive than forged parts, or parts made by other casting processes. The value inherent in the foam cast process versus other processes is seen in tighter tolerances, weight reduction and as-cast features which all results in less machining and cleanup time. Many castings that require milling, turning, drilling and grinding can be made in the foam cast process with only 5-8mm of machine stock.
• Generally, 500-1000 pieces per year is the minimum production run to be economical. Prototyping runs, however, may be as few as 3-5 pieces for Fabricated Foam patterns or 20-100 pieces for Quick-Cut CNC machined aluminum tooling.
• Generally, 8 to 16 weeks is typical for completed tooling and first castings produced. After casting approval, 6 to 12 weeks is typical for production run start-up. Rapid prototyping methods can produce castings in as little as 2 to 3 weeks.
   

• Metal Casting
• Lost Wax Process
• Lost Foam Casting Process
• Development Trends

Process Information

• Pre-expansion Process
• Vacuum Condition in Lost Foam Casting

Technology Information

• Aluminum Casting Process
• Aluminum lost-foam casting production
• Casting with Aluminum & Magnesium alloys
• Iron Casting
• Technology over the Years

Consultants

• Casting Design
• Project Consultancy
• Lost Foam Casting Systems

Case Studies

• Cylinder Block
• Gripper
• Rapid Prototyping of Castings
• Development in China

Industry Guides

• Advanced Lost Foam Casting Technology

Project - Video Clips

• Process Steps
• Foam Preparation
• The full process operation
• Equipment Functions
• Process Demonstration
• Process explained

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