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lost foam casting

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Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006508
EISBN: 978-1-62708-207-5
... Abstract Lost foam casting is a sand casting process that uses an expandable polystyrene (EPS) pattern that embodies the positive shape of the part to be cast. Lost foam casting is especially suitable for fairly complex castings with many internal passages. This article discusses the advantages...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005254
EISBN: 978-1-62708-187-0
... Abstract This article discusses the sequence of operations for producing a foam pattern for casting. It provides information on expandable polystyrene (EPS), the most preferred material for manufacturing lost foam patterns. The article describes the major functions of pattern molding and...
Book Chapter

Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005287
EISBN: 978-1-62708-187-0
... Abstract Aluminum casting alloys are the most versatile of all common foundry alloys and generally have the highest castability ratings. This article provides an overview of the common methods of aluminum shape casting. These include gravity casting, die casting, sand casting, lost foam casting...
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003172
EISBN: 978-1-62708-199-3
..., dry sand molds, resin-bonded sand molds, and sodium silicate bonded sand. The article describes the casting processes that use these molds, including the no-bake process, cold box process, hot box process, the CO2 process, lost foam casting process and vacuum molding process. The casting processes...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006524
EISBN: 978-1-62708-207-5
... presents the advantages and disadvantages of green sand casting, permanent mold casting, semipermanent mold casting, and high-pressure die casting. A discussion on other casting processes, such as investment casting, lost foam, plaster mold casting, pressure casting, centrifugal casting, and semisolid...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005253
EISBN: 978-1-62708-187-0
.... castings lost foam casting expendable mold process expendable pattern method investment casting patternmaking permanent pattern method polystyrene replicast casting ceramic shell mold CASTING WITH EXPENDABLE MOLDS is a very versatile metal-forming process that provides tremendous freedom of...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005186
EISBN: 978-1-62708-187-0
...-casting processes. Source Ref 10 Table 7 General characteristics of casting processes See Fig. 1 for shape descriptions Characteristic Casting process Green sand Resin-bonded sand Plaster Lost foam Investment Permanent mold Die Part Material (casting) All All Zn...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005249
EISBN: 978-1-62708-187-0
... casting quality: As-cast surface finishes of 50 to 125 root mean square (approximately ISO N7 or N8) are readily obtained. By using flexible rubber patterns and incorporating the advantages of lost-wax techniques, slurry molding successfully produces intricate designs. The dimensional accuracy of...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0009015
EISBN: 978-1-62708-187-0
... Fig. 1 Chart of shape casting process In the case of an expendable old, made with bonded sand or other loose granular mold material, the patterns may be permanent as is typical in sand casting or expendable as in lost foam and investment casting. When patterns are permanent, the mold must be...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005306
EISBN: 978-1-62708-187-0
... terms of shape casting, the percentage of nonferrous shape casting tonnage is roughly as follows ( Ref 1 ): Aluminum high-pressure die casting, 54% Aluminum sand and permanent mold casting, 12% Zinc high-pressure die casting, 11% Aluminum lost foam casting, 10% Sand mold casting of...
Series: ASM Handbook
Volume: 1A
Publisher: ASM International
Published: 31 August 2017
DOI: 10.31399/asm.hb.v01a.a0006297
EISBN: 978-1-62708-179-5
...) printing, machining of sand molds, lost wax casting, and lost foam casting. This method is economical only for high-volume production, due to the high initial costs. As in all die casting, the process is inherently slow because the die cannot be opened until the casting is sufficiently cool...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006519
EISBN: 978-1-62708-207-5
... then introduced into the empty cavity created by the wax shape that has now been melted out. This is in contrast to the lost foam casting method, where the foam pattern is not melted out before the molten metal is introduced but during the introduction of the molten metal, thus the term lost foam...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005187
EISBN: 978-1-62708-187-0
... cores, but at this writing (2008), HPDC must be considered very limited with respect to application of disposable cores such as those applied to the sand and permanent mold processes. By assembling simple-to-mold shapes, the lost foam process has the ability to consolidate several complex cast...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005255
EISBN: 978-1-62708-187-0
... insect wax that melts at approximately 64 °C (147 °F). It is widely used for modeling and is also useful in pattern blends, contributing some of the same characteristics as comparable microcrystalline waxes. It is believed to be the original wax used for lost-wax casting, but today (2008) its use is...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006533
EISBN: 978-1-62708-207-5
... lost foam and investment casting processes. The schematic in Fig. 2 illustrates the flow chart of a simple sand molding process. Slower solidification combined with lower cooling rates occurs with sand casting as compared to other metal molding processes ( Table 2 ). In high-integrity castings, the...
Series: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005501
EISBN: 978-1-62708-197-9
... kinds of casting components. Some of the most common ones are sand casting, investment casting, die casting, permanent mold casting, lost foam casting, centrifugal casting, continuous casting, and direct chill casting. Each casting process has its own features. For example, for pressure die casting...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005260
EISBN: 978-1-62708-187-0
... of misruns, a vented mold works best and prevents the overuse of coatings for this purpose. During operation, coatings lose some of their texture, and thereby, the venting is lost unless the coating is repaired. This practice exposes the mold surface to coating buildup and overspray, which can result...
Series: ASM Handbook
Volume: 2B
Publisher: ASM International
Published: 15 June 2019
DOI: 10.31399/asm.hb.v02b.a0006568
EISBN: 978-1-62708-210-5
... 43.5 205 29.7 12.0 13.3 273 39.6 190 27.5 3.6 4.7 Lost foam Transfer case 257 37.3 201 29.1 6.0 11.8 197 28.5 177 25.7 0.0 5.6 VRC/PRC Front knuckle 309 44.8 234 33.9 10.7 15.6 297 43.0 225 32.6 6.5 6.7 Squeeze cast Front knuckle 286 41.4 218 31.6 9.5...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005261
EISBN: 978-1-62708-187-0
... completely, to avoid the problems described previously. The molds used in low-pressure casting can range from hard sand molds to lost foam flasks but are most typically constructed of tool steel or cast iron. In applications where only forced-air cooling is used, iron molds can be used very effectively and...
Book Chapter

Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005307
EISBN: 978-1-62708-187-0
... are produced by hot chamber die casting. Other methods include sand casting, permanent mold casting, plaster casting, spin casting (silicone rubber molds), investment (lost wax) casting, squeeze casting, continuous or semicontinuous casting, and centrifugal casting. Zinc alloy castings have also been...