EVAPORATIVE PATTERN CASTING

ADVANCED MANUFACTURING PROCESSES

(MEC350C)

Presented By;
Majid Razak Chasballi
Roll No:- ME-18-11

Department of Mechanical Engineering

Islamic University Of Science And Technology
Awantipora, J&K-192122
 CONTENT
 INTRODUCTION.

 PRINCIPLE.

 WORKING.

 APPLICATION.

 ADVANTAGES.

 DISADVANTAGES.

 REFERENCES.
 INTRODUCTION

 The evaporative pattern casting is one of the modern and hybrid casting
processes, which aims to minimize the production cost, and capable of
producing intricate shapes with less efforts in pattern making.

 Evaporative pattern casting is a sand casting process that uses foam a

replica of an item in order to evaporate in a sand mold in replacement of
molten metal.

 This casting process is also known as consumable or Eva-foam casting.It

is similar to investment casting.

 The most common evaporative pattern material used is polystyrene foam.

 PRINCIPLE
 The working of evaporative pattern casting is
achieved by producing a foam patter, which is
the replica of an item to be cast.
 This pattern is brushed with refractory
substances in order to add extra life to the
pattern when molten metal is poured or to make
it resistant to high temperatures.
 The pattern is then attached with sprues and
gates using adhesives. It is placed into a mold
surrounded and packed by sand.
 Another way of doing this is by dipping the
pattern into a ceramic slurry, just as investment
casting. it forms a shell around it when it dries.
 WORKING
 It has been observed that to make casting by EPC process are
divided into two main classes;
 1. Evaporative Pattern Production.
 2. Assembly and inspection.
 The first is pattern molding, in this when pattern are machined from a
block of polystyrene from with a device called heated wire.

 The second is inspection of the patterns produced industrially or

manually.In this dimensional accuracy and correctness of the shape are
inspected.

 Many a time EPC process involves casting of intricate shapes such

that a shape will be broken into segements pattern will be produced
from the segements.The pattern of segements are joined together with
glue.

 Now the third step is cluster assembly,in this refractory coating which
is made from highly refractory materials is sprayed on the patterns.
 Then the patterns are left to dry, the drying period is with in a matter
of seconds, maximum 15seconds, this is possible because of the
reducer which is usually methyl alcohol at 99% conc. That is
employed in the transfer of coating to spraying the patterns.

 The drying process is done.

 The sand mold is prepared with molding sand usually river sand
whose grains fineness number has been determined and some other
properties which molding materials should have like green strength,
refractioness, hot strength and so on.

 Casting materials are charged into the furnance and allowed to melt,
and solidification of the casting takes place inside the mold.
 The process of removing the casting from the mold is the
shakeout, while removal of sphere, runner bar and ingates
from the casting is the de-gating which is the last of all sees
to the cleaning and finishing of the casting.
 APPLICATION

 The application of the EPC process is dynamic. It has been

applied in the production of aluminum and its alloys.

 Iron founding also makes use of the process for production

of various products.

 Magnesium and it alloys are now being cast using the

method.
 ADVANTAGES

 One of the principal advantages of EPC Process is that the

casting sand can be reused.

  EPC Process does not present lines that separate molds into
several parts which are called parting lines.

 The EPC is an environmentally favorable process.

 DISADVANTAGES

 A new pattern is needed for every casting.

 Economic justification of the process highly dependent

upon the cost of producing patterns.
REFERENCES

 https://studentlesson.com/evaporative-pattern-casting-definition-
applications-working-advantages/

 https://www.intechopen.com/chapters/59140

 http://nptel.iitm.ac.in
THANK YOU