Technology of Special Foundry

Processes
3rd Year ME, NIFFT

Dr. Jagesvar Verma, Assistant Professor

Department of Manufacturing Engineering
National Institute of Foundry and Forge
Technology, Hatia, Ranchi
TEXT BOOKS:
1. R.A.Flinn, “Fundamentals of Metal casting”, Addison Wesley,
1963.

2. R.W. Heine, C.R.Loper & P.C. Rosenthal, “Principles of Metal

casting”, Tata McGraw Hill, 2001.

REFERENCE BOOKS:

1. R.A. Lindberg, “Processes and Materials for Manufacturing”,

4th Ed, Pearson Education, 2006.

2. P.N.Rao, “Manufacturing Technology: Foundry, forming and

welding”, 3rd Ed., Tata McGraw Hill, 2003.

3. ASM Handbook: Volume 15: Casting” 9th Ed., American

Society of Metals, Ohio, 2008.
Lost Foam Casting
Lost-foam casting (LFC):

Lost-foam casting: It has also different generic and

propriety names like:
lost foam, evaporative pattern casting, evaporative foam casting,
expandable pattern casting, full mold, etc. it is similar to
investment casting except foam is used for the pattern instead
of wax.

by Dr. Jagesvar Verma

 History of Lost-foam casting
➢In 1964, M.C. Flemings used unbounded sand with the process and
today this is known as lost foam casting (LFC), with LFC, the foam
pattern is molded from polystyrene beads.

➢ Most of the ferrous materials can be successfully casted using the

Lost Foam process, because the foam pattern and gating system must
be decomposed to produce a casting, metal pouring temperatures
above 1000°F are usually required.
Source: Manufacturing and Testing of Lost Foam Casting Products
by Dr. Jagesvar Verma
 ➢ Low Temperature metals can also be poured, but the part
size is limited Lost Foam process is suitable for series
production of aluminum (Al) castings up to about 20kg;
➢ For Iron (Grey, ductile and malleable): it is about 50kg

➢The name lost foam refers to the process for creating the foam
model of casting and then placing foam with molten metal and
process begin with polymer beads which must be expanded to a
control low density for molding.

Source: Manufacturing and Testing of Lost Foam Casting Products

by Dr. Jagesvar Verma
➢ Process steps:
❑Pattern is made up of polystyrene (Styrofoam) with density
about 18Kg/m3 – 20 Kg/m3.

If the density is too low, the resistance to bend will decrease

correspondingly, the pattern is out of shape easily. If the density is
to high the foam will increase the gas bubble amount, the casting
porosity defects easily to occur.

by Dr. Jagesvar Verma

❑Coated with gas permeable refractory slurry and dried, with
high temperature resistant breathable coating and then dried
(40-45°C) and formed a cluster model. It improve the strength
and rigidity to prevent the damager or deformation, it must
have permeability, refractoriness. Coating thickness usually in
the range of 1-2mm.

❑ Hard shell around the pattern is created

❑ Patterns are combined to make cluster models by sticking it

through special Glue sticks by manually or glue machining
by Dr. Jagesvar Verma
Coating with slurry Dried in drying room

by Dr. Jagesvar Verma

Patterns are combined to make cluster
models

by Dr. Jagesvar Verma

 Lost Foam Process

Source:
https://www.google.com/search?q=advantages+of+lost+foam+casting&rlz=1C1AVNE_enIN732IN732&sxsrf=ALeKk01vQnvwD1aj1o6yVGhQAG006jnifg:1585575190806&so
urce=lnms&tbm=isch&sa=X&ved=2ahUKEwi-y4zwp8LoAhVbfSsKHeVVDtcQ_AUoAXoECBAQAw&biw=1366&bih=657#imgrc=Jd8WkvRa-M0-2M
by Dr. Jagesvar Verma
 Advantages of lost foam casting are:
❑ Neither additives, binders, nor cores are required.
❑ One-piece flask
❑ Freedom of design
❑ Minimum handling of sand
❑ Scrap volumes are minimized; the equipment's footprint is
small; energy and manpower requirements, as well as
insurance premiums are reduced; as are the machining and
finishing requirements.

by Dr. Jagesvar Verma

 Advantages of lost foam casting are:

❑ New pattern is needed for every casting

❑ Process is highly dependent on cost of producing pattern
❑Patterns are also easily damaged and distorted as it is made of
low strength materials.

Source:
https://www.google.com/search?q=advantages+of+lost+foam+casting&rlz=1C1AVNE_enIN732IN732&sxsrf=ALeKk01vQnvwD1aj1o6yVGhQAG006jnifg:1585575190806&source=lnms&t
bm=isch&sa=X&ved=2ahUKEwi-y4zwp8LoAhVbfSsKHeVVDtcQ_AUoAXoECBAQAw&biw=1366&bih=657#imgrc=vhMSywiG6T5MYM
by Dr. Jagesvar Verma
 Application of lost foam casting are:
Tractor Parts casting Excavator tooth casting

Pump and Valve casting Casting and Art with no limit

Source: https://www.slideshare.net/GuruDutt1/lost-foam-casting-lfc-process
by Dr. Jagesvar Verma
End of This Chapter