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Gray Iron Lost Foam Casting Components

Gray Iron Lost Foam Casting Components

Material: Gray Cast Iron
Process: Lost Foam Casting
Weight: 9.80 kg
Application: Heavy Duty Truck

OEM Custom Gray Iron Lost Foam Casting Components from China Casting Company. Get a free quote now.

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Description

OEM Custom Gray Iron Lost Foam Casting Components from China

Lost Foam Casting, also called EPC (Expandable Pattern Casting) or LFC (Lost Foam Casting), is to put the foamed plastic pattern group coated with refractory coating into the sand box, and fill it with dry sand or self-hardening sand around the pattern. During pouring, the high-temperature molten metal makes the foam pattern pyrolyzed and “disappears” and occupies the exit space of the pattern, and finally the casting method of the casting is obtained. The casting produced by this method has high dimensional accuracy, smooth surface, and less pollution in the production process.


Lost foam casting is a near-net forming process, suitable for the production of more precise castings of various sizes with complex structures and unlimited alloys.


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

▶ 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.
  • Grey Cast Iron
  • Ductile Cast Iron
  • 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.

▶ Lost Foam Casting Procedure

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.
  1. Mold foam pattern making.
  2. Age pattern to allow dimensional shrinkage.
  3. Assemble pattern into a tree
  4. Build cluster (multiple patterns per cluster).
  5. Coat cluster.
  6. Foam pattern coating.
  7. Compact cluster in flask.
  8. Pour molten metal.
  9. Extract cluster from flasks.

▶ 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

▶ 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?

  • 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


gray iron lost foam casting components