✔ Greater design freedom for complex structural castings ✔ No draft angle is needed to save lots of cost. ✔ Function integrated foam patterns could be assembled from several pieces of foam patterns. ✔ Lost foam castings are near-net-shape process ✔ High flexibility through short set-up times ✔ Longer EPS mould service lives, hence lower proportionate tool costs ✔ Assembly and treatment costs are reduced by the omission of the treatment process, installation parts, screw connections, etc. ✔ Expansion of the scope of applications
What Are The Steps of Lost Foam Casting
1- Use foam molds to produce foam patterns and casting gating systems 2- Bond the patterns and runners to form a mold bundle module 3- Dip paint on the module 4- Dry the paint 5- Put the module into the sand box and fill it with dry sand 6- Vibrate molding in order to fill the cavity with dry sand and then compact the molding sand 7- Pouring molten metal to vaporize the foam and then forming the desired castings 8- After the castings have cooled, clean the castings. The dry sand can be recycled
What Casting Tolerances Could be Reached by Lost Foam Casting Process?
Generally speaking, the casting tolerances of lost foam castings are better than sand casting, but worse than shell mold casting and no-bake casting processes. For our foundry, we basically could achieve the following casting grades. But we would like to talk with you the specific castings and then decide what numbers we can provide for you. ✔ DCT Grade by Lost Foam Casting: CTG9 ~ CTG13 ✔ GCT Grade by Lost Foam Casting: CTG5 ~ CTG8