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Lost Foam Casting (also known as solid casting) is a combination of paraffin or foam models similar in shape and shape to casting into a model cluster, brushed with refractory coating and dried, embedded in dry quartz sand for vibration modeling, under negative pressure Under the pouring, the model is vaporized, the liquid metal occupies the position of the model, and a new casting method for forming a casting after solidification and cooling is formed.
The characteristics of lost foam casting are as follows:
In 1967, A. Wittemoser of Germany adopted the so-called "magnetic casting" because the binderless dry sand often collapsed during the casting process. In 1971, Nagano of Japan invented the V method (vacuum casting method). Inspired by this, today's lost foam casting uses vacuuming to fix the molding sand in many places. Therefore, in the past 20 years, lost foam casting technology has been rapidly developed worldwide.
High precision casting
Lost foam casting is a new process with no margin and precise molding. The process does not require mold taking, no parting surface, no sand core, so the casting has no flash, burr and draft angle, and the core is reduced. Size error caused by combination. The surface roughness of castings can reach Ra3.2 to 12.5μm; the dimensional accuracy of castings can reach CT7 to 9; the machining allowance is up to 1.5~2mm, which can greatly reduce the cost of machining, which can be reduced by 40 compared with traditional sand casting methods. % to 50% machining time.
Flexible design
Provides full freedom for the design of the casting structure. Highly complex castings can be cast by a combination of foam moldings.
Sand core without traditional casting
Therefore, there will be no uneven wall thickness of the casting due to the inaccurate size of the core or the inaccurate position of the lower core in the conventional sand casting.
Clean manufacturing
There is no chemical binder in the molding sand. The foam is harmless to the environment at low temperature, and the recovery rate of the old sand is over 95%.
Reduce investment and production costs
The weight of the casting blank is reduced, and the machining allowance is small.
Disadvantages and limitations
The lost foam casting process has the same shortcomings and limitations as other casting processes. Not all castings are suitable for production by the lost foam process, and specific analysis is required. The use of this process is mainly based on the following factors. 1. The larger the batch size of castings, the more economic benefits. 2. The order of good and poor applicability of casting materials is: gray cast iron - non-ferrous alloy - ordinary carbon steel - ductile iron - low carbon steel and alloy steel; through necessary preparations so as not to cause process experiments, The debugging cycle is too long. 3. The size of the casting mainly considers the scope of use of the corresponding equipment (such as the shaking table, sand box). 4. The more complicated the structure of the casting structure, the more the superiority and economic benefit of the lost foam casting process can be realized. For the case of the narrow cavity passage and interlayer in the structure, it is necessary to carry out the experiment before the lost foam process before the production can be put into production. .
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