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lost foam casting

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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...
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 in which the mold consists of an evaporative polystyrene foam pattern embedded in sand. It is especially well suited for making complex parts with convoluted features such as engine blocks, transmission cases, and cylinder heads. This article...
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
... processes, including pressure die casting, permanent mold, clay/water-bonded sand, chemically bonded sand, plaster mold, and investment casting. Important variations include molding and pattern distinctions such as lost foam (evaporative pattern), shell and V-mold, and process derivatives such as squeeze...
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003172
EISBN: 978-1-62708-199-3
... processes Squeeze casting Semisolid metal casting (rheocasting) (a) When sand or plaster complex cores are used instead of metal cores, the term semipermanent mold casting should be used. Fig. 13 Steps in the investment casting process Fig. 9 Lost foam pattern system...
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...
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...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.9781627082075
EISBN: 978-1-62708-207-5
Book Chapter

Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005256
EISBN: 978-1-62708-187-0
... of the investment casting process in terms of molding but with an expendable pattern made from high-quality expanded polystyrene (EPS) as in lost foam (instead of the lost wax pattern of investment casting). The EPS pattern is coated in ceramic slurry and then fired to produce the ceramic mold. The firing process...
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
... 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 separable into two or more parts in order to permit...
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
... 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 to Cu Al to cast iron All Zn to cast iron Zn to Cu Porosity and voids...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005308
EISBN: 978-1-62708-187-0
... the articles “Investment Casting” and "Replicast Molding" and the discussion of the lost foam process in the article “Lost Foam Casting” in this Volume). The pattern equipment (tooling) needed to make a casting includes the pattern and may also include one or more core boxes. Core boxes are used to make...
Book Chapter

Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005251
EISBN: 978-1-62708-187-0
..., the sand or mold aggregates are held together during pouring by the pattern itself (as in lost-foam casting) or by the use of an applied force (as in vacuum molding and magnetic molding described here). Unbonded (or no-bond) molding processes involve free-flowing mold particles and do not require binders...
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
..., which makes it generally advantageous in ferrous casting applications. It retains water to a higher temperature (1000 °C, or 1832 °F) compared to Southern bentonite (700 °C, or 1292 °F). When the sections of the mold reach these temperatures, the bonding power of the bentonite is lost, and it is called...
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
.... In 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...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005242
EISBN: 978-1-62708-187-0
.... Alternatively, the pattern may be expendable, as in the case of lost foam patterns that evaporate during casting. In lost foam casting, the expendable foam pattern can be placed in one flask or container to form the mold. This eliminates the need for cope and drag sections that are required in removing...
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
... engineering applications. The metal is 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...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005351
EISBN: 978-1-62708-187-0
... be a major contributor to scrap castings and lost productivity and profitability for the foundry. For example, the presence of dross, inclusions, or particulate impurities detracts from the natural fluidity of any melt ( Fig. 1 ) ( Ref 1 ). Mechanical properties of the cast product can also be degraded...
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
..., 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 configurations into one...
Series: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002423
EISBN: 978-1-62708-194-8
... with the example of machined versus cast parts, a replica of the part can be machined from expanded polystyrene and the lost foam casting method can be used to produce a “real” casting. This casting possesses all of the significant characteristics of the yet-to-be manufactured production parts. More details...
Series: ASM Handbook
Volume: 2B
Publisher: ASM International
Published: 15 June 2019
DOI: 10.31399/asm.hb.v02b.a0006553
EISBN: 978-1-62708-210-5
... ): 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 copper alloys, 10% Magnesium high-pressure die casting, 3% High-pressure die casting of aluminum is a growing...