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Manufacturing and Testing of Lost Foam Casting Products

Article  in  International Journal of Scientific and Engineering Research · September 2014

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 ISSN 2319-8885
Vol.03,Issue.23
September-2014,
Pages:4643-4647
www.semargroup.org,
www.ijsetr.com

Manufacturing and Testing of Lost Foam Casting Products

D. DEVSINGH
M.E, Associate Professor, CMRIT, Hyderabad, India, Email: devsingh209@gmail.com.

Abstract: The Lost foam process (LFP) / lost foam casting (LFC) also known as the evaporative pattern process is mostly used
to produce high volumes of complex automotive components. This process is originated about 58 years back. Polystyrene foam
pattern is embedded in traditional green sand (full mould process). Later in 1964 unbounded sand is used in this process (Lost
foam casting process).In this project work patterns are made in the form of tensile test specimens with thermocole material. Two
types of sands are utilized. One types of vibration, vertical cum round horizontal vibrations systems are used for ramming
purpose. The specimens made with thermocole are pasted withgypsum, dried then embedded in the sand contained in tins. After
vibrating for different time intervals in the case of different tins, pure aluminium in the molten condition is poured. Waited till it
solidified. Then the specimens are taken out from the tins, cleaned by chipping the shell formed (gypsum). These specimens are
given suitable tapering, turning and made into tensile specimens. Mechanical properties like hardness on Rockwell B scale,
ultimate tensile strength, compressive strength, Impact strength are found using respective machines. Results are plotted in the
form of graphs between time of vibration and properties in the case of each sand. The results are analyzed and conclusions are
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Keywords: Recommender System; Social Tagging; User Profile; Explicit Rating; Resource Recommendation.

I. INTRODUCTION gating system must be decomposed to produce a casting,

In 1964, M.C. Flemings used unbounded sand with the
process. This is known today as lost foam casting (LFC).
With LFC, the foam pattern is molded from polystyrene
beads. LFC is differentiated from full mold by the use of
unbounded sand (LFC) as opposed to bonded sand (full mold
process). Currently, more foundries in North America use
the LFC process that the full mold process. In his „1987 AFS
Silver Anniversary Paper, Flemings wrote: "During the late
„70s and into the early „80s, driven by the need for weight
and cost reduction, interest in the process by automotive
foundries increased dramatically”. The lost foam process
(LFP) also known as the evaporative pattern process is
mostly used to produce high volumes of complex automotive
components. This process is originated about 58 years back.
Polystyrene foam pattern is embedded in traditional green
sand (full mould process).later in 1964 unbounded sand is
used in this process (Lost foam casting process).
II. CASTABLE MATERIALS
Generally, all ferrous materials can be successfully cast
using the Lost Foam process. Because the foam pattern and
metal pouring temperatures above 1000°F are usually
required. Lower Temperature metals can be poured, but part
size is limited Lost Foam process is suitable for series
production of aluminum castings up to about 20kg; iron
(Grey, ductile and malleable) to about 50kg and copper based
alloy castings.
 Aluminum: 356 - 319 - 355 - 333
 Gray Iron: Class 25 - Class 30 - Class 35 - Class 50
 Ductile Iron - A D I - Steel - Low Carbon Steels
Because of the possibility of carbon pickup, the process is
unsuitable for most low and medium carbon steel castings but
austenitic manganese steel and other high carbon steel
castings can be made satisfactorily. In addition, very low
carbon ferrous castings will require special processing.
III. VERTICAL CUM HORIZONTAL ROUND
VIBRATOR
Shieve shaker is one of the vertical cum horizontal round
vibrator as shown in Fig.1. It consists of a motor, which
coupled to the machine via gears.

Copyright @ 2014 SEMAR GROUPS TECHNICAL SOCIETY. All rights reserved.

 D. DEVSINGH
2. Specifications of Electric Muffle Furnace:
Capacity : 4 kg (aluminium melting).
Panel board : K Type thermo couple.
K Type controller digital upto 12000 C.
Heating element: A-1 Kanthal element upto 1240 , skin
temperature.
Electrical : Air break controller 45 Ams, single phase 230
volts, 3000 watts.
Lining : Insulating bricks lining, M.S body with painting 200
length, 150 dia, SS 304, melting pot with lifting tongs.

IV. MELTING POT (CRUCIBLE)

Crucible is a container which is used for melting the raw
material. It is made up of graphite. It can withstand at high
temperatures but not used in this project.
Fig.1. Vertical Cum Horizontal Round Vibrator.
A. Temperature Indicator
A. Specifications of vertical cum horizontal round Temperature indicator is an instrument used for measuring
vibrator the temperature of the molten metal as shown in Fig.3. Its
Name =J.M power Electric works measuring capacity is around 20000c. There are a large
H.P =0.25 number of different time temperature indicators available in
Phase =single the market, based on different technologies. Some devices
Current =1.5 amp are based migration of dye through a filter paper, while
Voltage =220 v others contain pouches with bacterial fluids that change color
Frequency = 50 Hz when certain time-temperature combinations have been
Speed =1440rpm reached.

B. Types of Furnaces
 Blast type furnace
 Cupola furnace
 Bessemer furnace
 Open hearth furnace
 Electric muffle furnace
 Pit furnace

1. Electric Muffle Furnace: Furnace is a combustion

chamber in which coal or charcoal is burnt. Different types of
furnaces are used for melting different types of metals as
shown in Fig.2. Furnaces are usually heated to desired
temperatures by conduction, convection, or blackbody
radiation from electrical resistance heating elements.

Fig.3. Temperature Indicator.

B. Thermocole Sheets
Foamed polystyrene bead (thermocole) containing 92%
carbon and about 8% hydrogen and very little vaporization
products converts in to ash after burned is used as material to
make pattern as shown in Fig.4.
Specifications:
THICKNESS=20 mm sheets

C. Rockwell Hardness Testing Machine

Hardness test in the case of RockWell testing is based on
the depth of plastic deformation under load as shown in
Fig.5. It depends on Type of load and indenter used same
Fig.2 Muffle Furnace.
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.23, September-2014, Pages: 4643-4647
 Manufacturing and Testing of Lost Foam Casting Products
material will give different values measured in B and C
scales. This is the not case with the Brinnel hardness test.
Hard steel balls of diameters 1 to 10mm are used as
indenters. For a given material same rockwell hardness
number will use usually diameter of ball is
2.5mm,5mm,10mm.Load applied depends on type of
material used. The Rockwell hardness test method consists of
indenting the test material with a diamond cone or hardened
steel ball indenter. The indenter is forced into the test
material under a preliminary minor load of usually 10 kgf.
When equilibrium has been reached, an indicating device,
which follows the movements of the indenter and so responds
to changes in depth of penetration of the indenter, is set to a tensile load. The specimen stretched under load until it
datum position. While the preliminary minor load is still
applied an additional major load is applied with resulting
increase in penetration. When equilibrium has again been
reach, the additional major load is removed but the
preliminary minor load is still maintained. Removal of the
additional major load allows a partial recovery, so reducing
the depth of penetration.
Fig.4. Thermocole sheets.
Fig.5. Rockwell Hardness Machine.
The permanent increase in depth of penetration, resulting
from the application and removal of the additional major load
is used to calculate the Rockwell hardness number. Hardness
measurement can be defines as macro, micro or nano scale
according to the forces applied and displacement obtained.
Measurement of macro hardness of materials is a quick and
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.23, September-2014, Pages: 4643-4647
simple method of obtaining mechanical property data for the
bulk material from a small sample. It is also widely used for
the quality control of the surface treatment process.
D. Universal Testing Machine
A material response to the tensile load is determined by
conducting tensile test on Universal Testing Machine (UTM).
The machine is also used for compression and shear tests. To
conduct a test, one end of the standard specimen is attached
to movable crosshead with other end fixed to a stationary
member as shown in Fig.6. The cross head is driven such that
is stretch the specimen apart i.e. the specimen subjected to
breaks. A universal testing machine, also known as a
universal tester, materials testing machine or materials test
frame, is used to test the tensile stress and compressive
strength of materials. It is named after that fact that it can
perform many standard tensile and compression test on
materials, components and structures. Tensile testing
was done using ASME Section IX-2004 standards. The
equipment used was a UTM Machine model UTN-40 with a
maximum capacity of 400kN..The welded specimen was
prepared according to the procedures given in ASME Section
ix-2004.
Un-axial tensile test is known as a basic and universal
engineering test to achieve material parameters such as
ultimate strength, yield strength, % elongation, % area of
reduction and Young's modulus. These important parameters
obtained from the standard tensile testing are useful for the
selection of engineering materials for any applications
required. The tensile testing is carried out by applying
longitudinal or axial load at a specific extension rate to a
standard tensile specimen with known dimensions (gauge
length and cross sectional area perpendicular to the load
direction) till failure. The applied tensile load and extension
are recorded during the test for the calculation of stress and
strain. A range of universal standards provided by
Professional societies such as American Society of Testing
and Materials (ASTM), British standard, JIS standard and
DIN standard provides testing are selected based on
preferential uses.
Fig.6. Universal Testing Machine.
 D. DEVSINGH
Each standard may contain a variety of test standards V. EXPERIMENTAL ANALYSIS
suitable for different materials, dimensions and fabrication A. Working Procedure
history. For instance, ASTM E8: is a standard test method for Step 1: Pattern Drawing
tension testing of metallic materials and ASTM B557 is Draw the pattern drawing as per the requirement using the
standard test methods of tension testing wrought and cast Auto CAD or PRO-E as shown in Fig.8.
aluminum and magnesium alloy products Flat transverse
tensile test specimens were cut, from such welded specimens,
for the comparison of their Ultimate Tensile Strength.

E. Digital Compression Testing Machine

The unit is compact, making its useful for site applications.
The digital machines are provided with a pace rate indicator
to indicate pace rate on a Bar Graph. With a little experience,
the pace rate can be manually while the test is in progress.
The loading unit is of fully welded construction having a
cross head, base and solid plates. The hydraulic jack is fixed
to the base. The platens of the machine are hardened, ground
and polished. The upper platen is provided with self-aligning
action. To facilitate testing of various size specimens,
suitable size spacers are provided. The two speed pump
facilitates rapid approach of the platens for daylight closure
and also provides comprehensive control over the application Fig.8. Drawing of Pattern.
of load. A control valve provides fine control over the
loading rate for accuracy of pacing. B. Ramming Time for Each Tin Box
TABLE IV: Ramming Time for Fine Sand
F. Impact Testing Machine (Charpy)
The Charpy impact test, also known as the Charpy V-notch
test, is a standardized high strain-rate test which determines
the amount of energy absorbed by a material during fracture.
This absorbed energy is a measure of a

TABLE V: Ramming Time for Ordinary Sand

Fig.7. Impact Testing Machine.
given material's notch toughness and acts as a tool to study
temperature-dependent ductile-brittle transition as shown in
Fig.7. It is widely applied in industry, since it is easy to
prepare and conduct and results can be obtained quickly and
cheaply. The quantitative result of the impact tests the energy
needed to fracture a material and can be used to measure the
toughness of the material. There is a connection to the yield
strength but it cannot be expressed by a standard formula.
Also, the strain rate may be studied and analyzed for its
effect on fracture.
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.23, September-2014, Pages: 4643-4647
C. Compressive Test
When a specimen of material is loaded in such a way that
it extends it is said to be in tension. On the other hand if the
material compresses and shortens it is said to be
in compression. On an atomic level, the molecules
or atoms are forced apart when in tension whereas in
compression they are forced together. Since atoms in solids
always try to find an equilibrium position, and distance
between other atoms, forces arise throughout the entire
material which oppose both tension or compression. The
phenomena prevailing on an atomic level are therefore
similar. The "strain" is the relative change in length under
applied stress; positive strain characterizes an object under
tension load which tends to lengthen it, and a compressive
stress that shortens an object gives negative strain. Tension
tends to pull small sideways deflections back into alignment,
while compression tends to amplify such deflection
into buckling.
 Manufacturing and Testing of Lost Foam Casting Products
By definition, the ultimate compressive strength of a
material is that value of uniaxial compressive stress reached
when the material fails completely. The compressive strength
is usually obtained experimentally by means of
a compressive test. The apparatus used for this experiment is
the same as that used in a tensile test. However, rather than
applying a uniaxial tensile load, a uniaxial compressive load
is applied. As can be imagined, the specimen (usually
cylindrical) is shortened as well as spread laterally. A Stress– [1] AFS Homepage at the University of Missouri-Rolla.
strain curve is plotted by the instrument and would look
similar to the following Fig.9:
Fig.9. stress strain diagram.
VI. RESULTS AND GRAPHS
A. Graph for Compressive Strength
Graph for Compressive Strength as shown in Graph.1.
 Red line for fine grain sand
 Green line for ordinary sand
ramming can be selected and precise castings can be
produced.
 Surface finish in both sand is good.
 Mechanical properties of LFC products obtain by fine
grain sand are better than the LFC products obtain by
ordinary sand.
VIII. REFERENCES
[2] T.S. Piwonka (report author), H.W. Hayden on January
12, 1996 and their report about: Morikawa Industries
Corporation 150, Imojiya Koshoku City, Nagano 387,
Japan.
[3] O. Gurdogan, H. Huang, H. U. Akay Technalysis
Incorporated, Indianapolis,
[4] Indiana. W. Fincher, V. E. Wilson Lufkin, Texas. “Mold
filling analysis for ductile iron lost foam castings” Presented
at 1996 Casting Congress April 20-23, 1996, Philadelphia,
PA USA
[5] Workshop technology- Vol.1&2 by S.K.Hazra
Choudhary.
[6] Metallurgy and Mateial Science by Pakirappa.
[7] www.google.com.
[8] Indian Foundry Technology Journal (Technical Paper
IIT Roorkee).
[9] Dieter.H.B, et al. The British foundry men,
1968.Now.413P.
[10] Butler.R.D and Pob.R.J The British foundry men. 1964.
Apr.178P.
[11] Srinagesh.K, et al. Modern Castings. 1966. Feb.99P.
[12] Jain and Jain, Engineering Chemistry, 1991 Dhanpatirai
& Sons, Naisarak, Delhi.

Graph.1.Compressive strength.

VII. CONCLUSIONS
 Lost Foam Process is an advanced method in which
the other ingredients are not desired in the case of
traditional sand moulding process. Also moulding
flasks i.e. cope and drag, gating assembly are not
required.
 The variation in properties with regard to different
ramming timings in the case of two types of sands and
two types of vibrations are noted.
 When aluminium castings of desired properties are
required, particular type of sand, vibrations, time of

International Journal of Scientific Engineering and Technology Research

Volume.03, IssueNo.23, September-2014, Pages: 4643-4647

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