Report Workshop (Lost Foam Casting)

INTRODUCTION
The Lost Foam casting process originated in 1958 when H.F.

Shroyer was granted a patent for a cavity-less casting method,
using a polystyrene foam pattern embedded in traditional green
sand. The poured molten metal decomposes the polystyrene foam
pattern left in the sand. The metal replaces the foam pattern,
exactly duplicating all of the features of the original pattern. Like
other casting methods, this requires that a pattern be produced for
every casting poured because it is evaporated (lost) in the
process.
Generally, all ferrous and non-ferrous materials can be
successfully cast using the Lost Foam process. Because the foam
pattern and gating system must be decomposed to produce a
casting, metal pouring temperatures above 1000F are usually
required. Lower temperature metals can be poured, but part size is
limited. In addition, very low carbon ferrous castings will require
special processing.
Lost Foam castings can be produced in most all metals from a
fraction of a pound up to thousands of pounds. Slightly more
advanced techniques are used for very large castings.
The expendable-pattern casting process uses a polystyrene
pattern, which evaporates upon contact with molten metal to form a
cavity for the casting. The process is also known as evaporativepattern or lost-pattern casting, and under the trade name Full-Mold
process. It was formerly known as the expanded polystyrene
process and has become one of the more important casting
processes for ferrous and nonferrous metals, particularly for the
automotive industry.
The evaporative-pattern process has a number of advantages over
casting methods:
1. The process is relatively simple because there are no parting
lines, cores, or riser systems; hence it has design flexibility.
2. Inexpensive flasks are sufficient for the process.
3. Polystyrene is inexpensive and can be easily processed into
patterns having complex shapes, various sizes, and fine
surface details.
4. The casting requires minimum finishing and cleaning
operations
5. The process can be automated and is economical for long
production runs. A major factor is the cost to produce the die
used for long production runs. A major factor is the cost to
produce the die used for expanding the polystyrene beads to
make the pattern.
Typical applications for this process are cylinder heads,

crankshafts, brake components and manifolds for automobiles, and
machine bases. Aluminum engine blocks and other components for
General Motors Saturn automobiles are made by this process.
Recent developments include the use of polymethylmethacrylate
(PMMA) and polyalkylene carbonate as pattern materials for ferrous
castings. New developments in evaporative-pattern casting include
production of metal-matrix composites. During the process of
molding the polymer pattern, fibers or particles are embedded
throughout. These become an integral part of casting. Further
techniques include modification and grain refinement of the casting
by the use of grain refiners and modifier master alloys within the
pattern while it is being molded
SAFETY PRECAUTIONS:
Wear safety shoes if heavy work is being done.

Wear clothing suited for the job, wear shoes with thick soles.
Do not wear rings, watches, bracelets or other jewelry that
could get could get caught in moving machinery.
Do not wear neckties or loose turn clothing of any kind.
Wear shirts or uppers with sleeves cut off or rolled above the
elbows.
If material is rough and sharp then gloves must be work place
or handle material.
Wear leather glove, apron and face shield during pour molten
metal
WORKING PROCEDURE
1. The Styrofoam patterns is made by using polystyrene
2. The parts of foam patterns is glued together along with
sprue/ runner/ ingate, as required
3. The pattern is placed in silica sand, taking care to compact
the sand about the pattern
4. Molten metal (aluminum) is casted into the pattern. The
foam is evaporated and escaped through the normal
routes gas evacuates through
5. After that, the part is left until its cool down and solidified
6. After it fully solidified, the sand is removed. Then the
product is been taken out from the sand.
7. The product is observed for any casting defects.
RESULTS AND DISCUSSION

During lost foam casting method is carried out, there are numerous
defects have been identified .The defects will be discussed and
countermeasures or remedies was taken to overcome defects in
foam casting.
Porosity
Porosity is thought to be severe in aluminum alloy castings
produced by lost foam process due to the pyrolysis of the
polystyrene foam pattern during pouring, which results in
detrimental effect in mechanical property. The slow solidification
rate promotes the formation of gassing pin holes, and relative
weakness of the thermal gradients can cause micro-shrinkage if the
outline of the part complicates feeding in the lost foam casting.
Countermeasures
One of the methods to eliminate the porosity is to apply high

pressure to the molten metal like an isostatic forging during
solidification
Applying external pressure was effective in decreasing the
porosity and increasing the elongation of the lost foam
casting.
Sand Inclusion
Sand inclusion is also called as sand hole, which is kind of metal
casting defect. It looks like small or middle holes with a sand grain
in the internal or on the surface of casting. If the sand molds or cores
have been overbanked, then their surfaces will become more fragile because the
adhesive will lose its stickiness, which will cause some sand inclusion defects.
Countermeasures
Metal fill glue, fill agent

Metal-filled glue contain quartz and metal components, so
casting surface after filled by this glue will have a certain
hardness, and it can stand further machining process and a
temperature of 125 to 200 Celsius degree. Repairing with
metal filled glue is very common method in iron and steel
foundries in China.
Electrical welding
Welding is used for repairing middle or large sand inclusion.
After welding, the positions with sand holes will still keep good
strength and can stand the high temperature as metal.
Misruns
Incompletely formed casting due to premature solidification of metal
before the mold is filled. When the metal is unable to fill the mold
cavity completely and thus leaving unfilled portion called misrun. A
cold shunt is called when two metal streams does not fuse together
properly.
Countermeasures
Adjust proper pouring temperature
Modify design
Modify gating system
CONCLUSION
The casting seems like very easy. But it is difficult to make. Every
step is interconnected with other process. If any process has not
been completed well, it will lead to unqualified casting. Therefore,
for the newly purchased lost foam production line enterprise, the
good training and reasonable management systems are very
important. So, we can use this casting process to contribute
innovative ideas for producing foundry product and automation
solution that meet market environment.
REFERENCE:
Peter Beeley (2001). Foundry Technology. Oxford, England:
Butterworth Heinemann
C.W Ammen (2000). Metal Casting. New York City, NY:
McGraw-Hill
J.Campbell (2003). Castings. Oxford, England: Elsevier
Butterworth Heinemann
http://www.instructables.com/id/General-Steps-to-SandCasting/
http://myfordboy.blogspot.my/p/metal-casting-tips-andfaq.html

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INTRODUCTION

The Lost Foam casting process originated in 1958 when H.F.

Typical applications for this process are cylinder heads,

Wear safety shoes if heavy work is being done.

RESULTS AND DISCUSSION

One of the methods to eliminate the porosity is to apply high

Metal fill glue, fill agent

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