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Journal articles on the topic 'Lost foam casting'

Author: Grafiati

Published: 4 June 2021

Last updated: 16 February 2022

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1

Chen, Hong Ze, Hong Zhao Dong, and Zhong De Shan. "Numerical Simulation and Optimization Technology of Lost Foam Casting." Advanced Materials Research 936 (June 2014): 1681–86. http://dx.doi.org/10.4028/www.scientific.net/amr.936.1681.

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The filling and solidification process of casting that is closely related to lots of casting defects and has significant effect on the mechanical properties of castings. In this paper, the research status and development direction of numerical simulation technology of casting, especially of lost foam casting were reviewed and discussed. Also a brief introduction of the basic situations and product characteristics of several outstanding cast filling and solidification simulation softwares were summarized. In addition, the actual domestic application status of numerical simulation technology of lost foam casting in the foundry enterprises was analyzed and some suggestions were given as well.

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2

Niakan, Ali Asghar, M. H. Idris, Ali Ourdjini, and Majid Karimian. "Properties of Pressurized Lost Foam Casting of Al-11Si Alloy." Advanced Materials Research 383-390 (November 2011): 1730–34. http://dx.doi.org/10.4028/www.scientific.net/amr.383-390.1730.

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Lost Foam Casting, pressurized casting, solidification, mechanical properties. Abstract. The paper presents the result of investigation on aluminum-silicon (LM6) alloy cast using pressurized lost foam casting process. The study investigated the effect of pressure and sand size on hardness and roughness of the casting produced. Air pressure of 1, 2, 3 and 4 bars was applied on the solidifying alloy poured in mould of sand sized 40-60(AFS). The roughness and hardness of the casting was measured using Hobson (Surtronic 3+) and Vickers hardness testing machine respectively and reported in the average of ten readings. For roughness measurement of the solidified castings, measurement was conducted in 25mm run whilst 11kgf was applied for Vickers hardness indentation test. The results show that using of finer sand size besides applying pressure during solidification of LM6 alloy has significant influence on roughness and hardness of the alloy. Increasing the applied pressure and used of fine sand size expedited heat transfer from the melt to the mould and surrounding thus decreasing solidification time. Consequently, reduced casting surface roughness as well as increased in hardness.

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3

Znamenskii, L. G., O. V. Ivochkina, A. S. Varlamov, A. N. Franchuk, and A. A. Yuzhakova. "Domestic paints for lost foam casting." Bulletin of the South Ural State University Series ‘Metallurgy’ 17, no. 01 (2017): 58–64. http://dx.doi.org/10.14529/met170107.

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4

T. SIVA, PRASAD, and M. DEVAIAH. "EXPERIMENTAL STUDY OF LOST FOAM CASTING." i-manager’s Journal on Future Engineering and Technology 13, no. 4 (2018): 46. http://dx.doi.org/10.26634/jfet.13.4.14431.

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5

Shinsky, O. I., E. I. Marukovich, I. A. Shalevskaja, V. O. Shinsky, and S. I. Klimenko. "ECONOMY, ECOLOGY, ORGANIZATION OF FOUNDRY PRODUCTION BY LOST FOAM CASTING." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 4 (January 4, 2018): 53–59. http://dx.doi.org/10.21122/1683-6065-2017-4-53-59.

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The process of receipt of castings by Lost Foam Casting Process (LFCP) from the point of view of economic efficiency and possibilities of receipt of the high-fidelity and high quality castings with the forecast properties. Indexes of hazardous substances emissions at LFCP are defined, measures to purify are worked out and ecological safety of process is shown.

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6

Chen, Hong Ze, Zhong De Shan, and Hong Zhao Dong. "Research of Foam Pattern Processing for Lost Foam Casting." Applied Mechanics and Materials 331 (July 2013): 600–603. http://dx.doi.org/10.4028/www.scientific.net/amm.331.600.

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In the whole process of the LFC (or evaporative pattern casting, EPC), the quality of the foam pattern play a decisive role to the final casting quality. The present processing methods for the foam pattern are discussed, including foaming molding, manual cutting, and CNC machining, rapid prototyping, also the advantages and disadvantages of these processing methods are analyzed. As CNC machining become the main trend for foam pattern processing, some CNC machine oriented tools are summarized, including the hot wire foam cutter, the hot knife foam cutter, and the modified tools based on the traditional tools.

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7

Mirbagheri, S. M. H., S. Serajzadeh, N. Varahram, and P. Davami. "Modelling of foam degradation in lost foam casting process." Materials & Design 27, no. 2 (January 2006): 115–24. http://dx.doi.org/10.1016/j.matdes.2004.09.018.

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8

Mirbagheri, S. H. M., J. R. Silk, and P. Davami. "Modelling of foam degradation in lost foam casting process." Journal of Materials Science 39, no. 14 (July 2004): 4593–603. http://dx.doi.org/10.1023/b:jmsc.0000034154.00641.0b.

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9

Jeon, Joo Mae, Soo Jo Lee, Kyeong Hwan Choe, and Jeung-Soo Huh. "Gas Pressure Effect on Sand Collapse in Kinetic Zone of Lost-Foam Casting." Advances in Materials Science and Engineering 2020 (April 25, 2020): 1–9. http://dx.doi.org/10.1155/2020/5861017.

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Pressure of the kinetic zone is an essential factor for making defect-free castings in lost-foam casting process. The extremely high pressure causes many problems, such as reducing the melt velocity and inclusion of residual decomposition of the pattern in the castings, and very low pressure causes sand collapse. Therefore, the minimum gas pressure for preventing sand collapse is required. When the minimum gas pressure can be predicted, computer simulation becomes possible. Successful computer simulations can help reduce the number of trials and the lead time while designing new casting products. A preliminary sand experiment was conducted to predict the gas pressure and reduce the number of actual casting experiments. In this preliminary sand experiment, compressed air was used instead of gas in the kinetic zone. A new mathematical equation was proposed from the results of the preliminary sand experiment. The void ratio of the sand effect on the minimum gas pressure was included in the equation. An actual casting experiment was conducted by melting nodular cast iron to verify this equation. In the actual casting experiment, pressure of the kinetic zone in front of the metal tip was directly measured. The results obtained from the preliminary sand experiment and the actual casting experiment validated the equation.

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10

Marukovich, E. I., A. M. Branovitskiy, A. A. Kruglov, V. A. Dement’ev, and N. P. Sadovskiy. "PRODUCTION OF ROTARY ENGINES’ PARTS FROM ALUMINUM ALLOYS USING LOST FOAM CASTING PROCESS." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 6, 2018): 16–21. http://dx.doi.org/10.21122/1683-6065-2018-1-16-21.

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The production technology of casting details for rotary engine from the aluminum alloy АК12М2 is developed. The bulk density of expanded polystyrene to ensure the best quality of the surface of castings has been experimentally established. The lost foam casting shop was organized in the experimental department of the Institute.

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11

Druschitz, Alan P., and Harry Littleton. "Advanced Lost Foam Casting Processes and Materials." SAE International Journal of Materials and Manufacturing 2, no. 1 (April 20, 2009): 140–46. http://dx.doi.org/10.4271/2009-01-0213.

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12

Karimian, Majid, Ali Ourdjini, Mohd Hasbullah Idris, M. Bsher, and A. Asmael. "Effect of Pouring Temperature and Melt Treatment on Microstructure of Lost Foam Casting of AL-Si LM6 Alloy." Advanced Materials Research 264-265 (June 2011): 295–300. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.295.

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This paper presents the experimental investigation conducted on Al-Si cast alloy (LM6) cast using lost foam process. The main objective of the research is to investigate the effect of pouring temperature, section thickness and melt treatment on the microstructure of the lost foam casting of Al-Si alloy. Step pattern with five different sections was prepared from 20 kg/m³ density foam and poured at five different temperatures; 700, 720, 740, 760, and 780 with and without the addition of AlTiB as grain refiner. Analysis on microstructure, eutectic silicon spacing and porosity percentage were conducted to determine the effect of both parameters. The results show that pouring temperature has significant influence on the quality as well as microstructure of the lost foam casting of LM6 Al-Si alloy. Lower pouring temperature was found to produce finer microstructure casting. However, the addition of AlTiB as grain refiner did not affect the produced castings significantly whether in terms casting quality or microstructure.

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13

Xiao, Xiao Feng, Qiong Xue, Ke Feng Xiao, and Xiao Lan Hu. "LFC Mold Development of Complex Parts with Free-Form Surface." Advanced Materials Research 228-229 (April 2011): 532–36. http://dx.doi.org/10.4028/www.scientific.net/amr.228-229.532.

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This paper has analyzed key techniques in foam mold development for Lost Foam Casting for different types of casting, which are complex box, pipe faucet junction ,wear-resisting and refractory alloy steel casting, Focused on complex castings with free-form surface, key points during whole technical route, which includes three-dimensional modeling, foamed pattern design, mold design and CNC program, have been discussed by utilizing modeling & manufacturing module on Unigraphics. Because of its perfect free-form surface functions and plentiful toolpath operations in CNC programming, Foam mold of complex casting with free-form surface has been designed, manufactured and assembled successfully for LFC, Qualified foamed pattern of vortical shell has been produced successfully. Several effective methods and experiences have been achieved by utilizing CAD/CAM technology.

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14

Barone, M. R., and D. A. Caulk. "A foam ablation model for lost foam casting of aluminum." International Journal of Heat and Mass Transfer 48, no. 19-20 (September 2005): 4132–49. http://dx.doi.org/10.1016/j.ijheatmasstransfer.2005.03.031.

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15

Caulk, D. A. "A foam melting model for lost foam casting of aluminum." International Journal of Heat and Mass Transfer 49, no. 13-14 (July 2006): 2124–36. http://dx.doi.org/10.1016/j.ijheatmasstransfer.2005.12.007.

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16

Caulk, D. A. "A foam engulfment model for lost foam casting of aluminum." International Journal of Heat and Mass Transfer 49, no. 21-22 (October 2006): 3831–45. http://dx.doi.org/10.1016/j.ijheatmasstransfer.2006.04.015.

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17

Asmoro, Anan Tri. "Perbandingan Kualitas Hasil Pengecoran Metode Sand Casting Dan Metode Pengembangan Lost Foam Invesment Casting Dengan Variasi Bahan Pengikat Berdasarkan Analisis Hasil Pengecoran." Jurnal Teknik Mesin dan Pembelajaran 2, no. 1 (November 3, 2019): 117. http://dx.doi.org/10.17977/um054v2i1p117-123.

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Penelitian ini merupakan penelitian komparasi antara metode sand casting dan pengembangan metode lost foam investment casting dengan variasi bahan pengikat bentonit pada sand casting dan semen merah pada lost foam investment casting. Metode yang digunakan pada penelitian ini menggunakan metode pre experimental design dengan model intact group comparision dengan analisis deskriptif. Pengujian yang digunakan meliputi uji visual, uji kekersan vikers, dan struktur mikro. Adapun hasil dari penelitian ini menunjukkan pada uji visual didapatkan metode pengembangan lost foam investment casting memiliki kehalusan yang lebih baik dari sand casting. Berdasarkan nilai kekerasan vikers lost foam investment casting memiliki nilai kekerasan 61.07 HV lebih tinggi dari sand casting dengan nilai kekerasan rata-rata 55.85 HV. Berdasarkan nilai uji struktur mikro didapatkan lost foam invesment casting memiliki struktur butir yang lebih homogeny dibandingkan dengan sand casting.

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18

Li, Ji Qiang, Zhong Zhao, Zi Tian Fan, Zhi Xin Jia, Wen Liu, and Li Jun Liu. "Determination of Optimal Temperature for Defect-Free Casting of Aluminium in the LP-LFC Process." Applied Mechanics and Materials 101-102 (September 2011): 934–37. http://dx.doi.org/10.4028/www.scientific.net/amm.101-102.934.

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Fluidity of ZL101 aluminium alloys in the low-pressure lost foam casting (LP-LFC) process has been investigated by altering various temperature variables. The experimental results indicate that the LP-LFC process had fine fluidity, and the pouring temperature was lower than conventional lost foam casting. The effect of the metal temperature on the fluidity is marginal in the LP-LFC process. Excessive pouring temperature not only aggrandizes energy consumption but also deteriorates porosity defect. The success of casting cooling fin demonstrates the advantages of LP-EPC process in producing high-complicated castings.

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19

Li, Zhan Guo, Xue Chen Zhang, and Yao Chen Shi. "Study of Large Castings Lost Foam Online Non-Contact Detection." Advanced Materials Research 472-475 (February 2012): 809–12. http://dx.doi.org/10.4028/www.scientific.net/amr.472-475.809.

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This paper aimed at traditional large casting with lost foam detection which has slown speed and low efficiency problems, developed a new non-contact detection method which combined digital close range photogrammetry measurement techniques and grating projection measurement techniques, fulfilled a car wind screen board lost foam 3272mm x 1205mm x 555mm online detection, has produced non-contacted online detection method. The results showed that method with fast detection speed、high efficiency, and can satisfy the large castings lost foam online non-contact detection requirements.

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20

Kalyuzhnyy, P. B., S. O. Krotyuk, and M. T. Levchuk. "THE PRODUCTION TECHNOLOGICAL PROCESSES OF STEEL CAST PRODUCTS FOR SHUT-OFF VALVES BY CASTING ON LOST FOAM CASTING." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 6, 2018): 22–27. http://dx.doi.org/10.21122/1683-6065-2018-1-22-27.

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The peculiarities of technological processes of obtaining steel castings of shut-off valves by lost foam casting are described. It is shown that the dimensional accuracy of the casting «Valve Body DN80» exceeds 7-th accuracy class; the surface quality, mechanical properties and chemical composition of the steel completely meet the customer requirements. The test procedure for leakproofness of shut-off valves castings is given.

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21

Jezierski, Jan, Michał Jureczko, and Rafał Dojka. "The Impact of Process Factors on Creating Defects, Mainly Lustrous Carbon, during the Production of Ductile Iron Using the Lost-Foam Casting (LFC) Method." Metals 10, no. 8 (July 30, 2020): 1022. http://dx.doi.org/10.3390/met10081022.

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The purpose of this paper was to analyze the process factors affecting the occurrence of lustrous carbon defects in ductile cast iron castings when using the lost-foam casting (LFC) method. This phenomenon results in creating raw surface defects, which sometimes may even lead to cast iron scrapping. A series of trial melting batches were carried out for variable process assumptions. The analysis was performed to reflect, to the greatest extent possible, real foundry production conditions. Industrial tests were performed in Odlewnia Rafamet Sp. z o.o., Kuźnia Raciborska, Poland. The polystyrene patterns created by gluing components together, used in the tests, met the requirements of the high-tech lost-foam casting (LFC) process. The performed analysis allowed the obtaining of lustrous carbon defects in test castings as well as the determination of the process parameters with the highest impact on lustrous carbon inclusions in ductile iron castings. The test results were used to eliminate the possibility of creating a defect and thus directly improve the efficiency of the lost-foam casting (LFC) process used in the foundry.

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22

Liu, Zhi Ming, Yan Liu, and De Hui Liu. "Study on the Coating of Lost Foam Casting for Steel Casting." Advanced Materials Research 680 (April 2013): 267–70. http://dx.doi.org/10.4028/www.scientific.net/amr.680.267.

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The coating is one key technology of lost foam casting (LFC). This paper discussed the influences of refractory aggregate contents on strength, viscosity and other performances of LFC coating, and develops a high performance coating which can meet the requirement of LFC for steel casting. The results shown that with the content of the high bauxite increasing and the content of zircon powders decreasing, the strength, permeability and attached quantity of the coating increased. The best ratio of refractory aggregate is 70% high bauxite and 30% zircon powders. The optimal formula in the experiments is 70% high bauxite, 30% zircon powders, 3% sodium bentonite, 0.5% CMC and 5% ludox. This coating has good comprehensive performances to meet the requirements of LFC steel casting.

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23

Li, Li Jun, Jian Zhou, Zi Cheng Gao, Yi Hua Hu, and Ke Cheng. "Study of Lost Foam Casting of Reaper Underpan." Advanced Materials Research 239-242 (May 2011): 433–36. http://dx.doi.org/10.4028/www.scientific.net/amr.239-242.433.

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For obtaining higher quality casting, the lost foam casting is used to produce reaper underpan. While the raw materials are selected, the fireproof coating and sand are chosen well, the sand box is designed according to the technology, pouring system is calculated, under the above operation strictly, such as air hole can be avoided.

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24

Niakan, Ali Asghar, M. H. Idris, A. Ourdjini, and Majid Karimian. "Effect of Applying Air Pressure on Gas Porosity in Lost Foam Casting of Al-Si Alloy." Advanced Materials Research 628 (December 2012): 150–55. http://dx.doi.org/10.4028/www.scientific.net/amr.628.150.

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The paper presents the result of investigation on aluminum-silicon (LM6) alloy cast using pressurized lost foam casting process. The study investigated the effect of pressure and sand size on porosity of the casting produced. Air pressure of 1, 2, 3 and 4 bars was applied on the solidifying alloy poured in mould of sand sizes 16-30, 40-60, 60-100 (AFS). The porosities of casting were measured using optical microscope which was equipped with image analyzer. For porosity of castings, all surfaces of solidified castings were captured by digital camera for better observation. The results show that applying pressure during solidification of the LM6 alloy has significant influence on casting porosity of the alloy. By increasing the applied pressure, the porosity percentage based on gas porosity decreased when pressure was applied. Consequently, the removal rate of gas porosity improved by increasing the sand size to finer size 60-100 (AFS), so there is less gas porosity in samples. Besides, rising air pressure lead to fulfilling of molten which improves the casting porosity.

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25

Bichler, Lukas, Comondore Ravindran, and A. Machin. "Challenges in Lost Foam Casting of AZ91 Alloy." Materials Science Forum 426-432 (August 2003): 533–38. http://dx.doi.org/10.4028/www.scientific.net/msf.426-432.533.

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26

Yao, X., and S. Shivkumar. "Mould filling characteristics in lost foam casting process." Materials Science and Technology 13, no. 10 (October 1997): 841–46. http://dx.doi.org/10.1179/mst.1997.13.10.841.

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27

Nesterov, N. V., B. S. Vorontsov, and P. N. Nesterov. "Preparation of Bimetal Objects by Lost Foam Casting." Chemical and Petroleum Engineering 54, no. 5-6 (September 2018): 448–51. http://dx.doi.org/10.1007/s10556-018-0501-4.

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28

TABIBIAN, S., E. CHARKALUK, A. CONSTANTINESCU, F. SZMYTKA, and A. OUDIN. "TMF criteria for Lost Foam Casting aluminum alloys." Fatigue & Fracture of Engineering Materials & Structures 36, no. 4 (October 2, 2012): 349–60. http://dx.doi.org/10.1111/ffe.12006.

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29

Shivkumar, S., L. Wang, and D. Apelian. "The lost-foam casting of aluminum alloy components." JOM 42, no. 11 (November 1990): 38–44. http://dx.doi.org/10.1007/bf03220435.

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30

Jiang, Wenming, and Zitian Fan. "Novel technologies for the lost foam casting process." Frontiers of Mechanical Engineering 13, no. 1 (March 2018): 37–47. http://dx.doi.org/10.1007/s11465-018-0473-2.

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31

Jagoo, S., Comondore Ravindran, and Dennis Nolan. "Fold Defects in Aluminum Alloy A356 Lost Foam Casting." Advanced Materials Research 15-17 (February 2006): 1–6. http://dx.doi.org/10.4028/www.scientific.net/amr.15-17.1.

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In the lost foam casting (LFC) of aluminum alloys, the expandable polystyrene (EPS) foam characteristics (foam composition, polymer processing and bead fusion) influence the formation of deleterious fold defects in the final casting. In this research, four types of EPS beads were investigated: (1) the regular EPS beads, (2) 2wt% hexabromocyclododecane and 2wt% dicumyl peroxide added to the EPS beads during the polymerization process, (3) 2wt% silicaalumina blended to EPS beads after the pre-expansion process of the beads and (4) 2wt% hexabromocyclododecane blended to EPS beads after the pre-expansion process of the beads. The density of the regular and modified EPS beads was kept constant at 25.63 kg/m3. Aluminum alloy A356 was poured at 1023 K into the window pattern. The window patterns with regular EPS beads did not fill completely and had identifiable carbon/oxide defects on the surface. The window patterns with the additives were completely filled with a few surface defects. From thermogravimetric analysis (TGA), it was found that the EPS beads with silica-alumina had a reduced onset temperature of degradation of EPS (from 634 K to 618 K) and a reduced activation energy (from 188 kJ/mol to 147 kJ/mol) relative to the regular beads. In the organic brominatedmodified EPS (both through blending and polymerization), it was found that the value of the preexponential (rate equation) was significantly increased. Through light optical microscopy (LOM) and scanning electron microscopy (SEM), it was found that the polymerization process additives increased the degree of bead fusion whereas the post pre-expansion additives decreased the degree of bead fusion. Finally, the EPS beads treated during the polymerization process produced castings with the least overall surface, subsurface and internal defects.

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32

Liu, X. J., S. H. Bhavnani, and R. A. Overfelt. "Simulation of EPS foam decomposition in the lost foam casting process." Journal of Materials Processing Technology 182, no. 1-3 (February 2007): 333–42. http://dx.doi.org/10.1016/j.jmatprotec.2006.08.023.

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33

Zhao, Zhong, and Zi Tian Fan. "Influence of Vibration on the Heat Transfer of Lost Foam Casting Filling." Advanced Materials Research 418-420 (December 2011): 1618–21. http://dx.doi.org/10.4028/www.scientific.net/amr.418-420.1618.

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The vibration is superimposed to the filling process of aluminum and magnesium alloy in lost foam casting, and the flow lengths and the molten metal temperatures of the flow front are collected, and they compared with no-vibration. The results show that the vibration can significantly improve the filling capacity of the aluminum alloy, magnesium alloy in lost foam casting. Compared to the samples without vibration, the flow lengths of A356 alloy with vibration in lost foam casting increased by 33% and that of AZ91D alloy increased by 15%.The heat transfer of molten metal on the flow front was analyzed, and it indicates that the vibration energy extends the filling time of the molten metal on the flow front in lost foam casting.

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34

Zhou, Jian, Li Jun Li, Jian Wen Yi, and Ming Yang. "Lost Foam Casting of Hydroturbine Blades Based on CAE." Applied Mechanics and Materials 71-78 (July 2011): 694–97. http://dx.doi.org/10.4028/www.scientific.net/amm.71-78.694.

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The article studies the method which hydroturbine part is manufactured by lost foam casting for obtaining higher quality product.The lost model material is polystyrene foam plastics,the EPS diameters are selected in 0.5-0.76mm,the casting raw material is lower carbon martensite stainless steel(ZG06Cr13Ni4Mo).The style of open pouring system is adopted, ∑Fin-gate：∑Fcross-gate：∑Fdown-sprue=1：1.1：1.2, fireproof coating is mixed and coated,square sand box is used. The pouring temperature of liquid is 1600-1650°C.If the technology is strictly according to the design,good quality casting can be gotten.

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35

Niakan, Ali Asghar, M. H. Idris, Majid Karimian, and A. Ourdjini. "Effect of Pressure on Structure and Properties of Lost Foam Casting of Al-11Si Cast Alloy." Applied Mechanics and Materials 110-116 (October 2011): 639–43. http://dx.doi.org/10.4028/www.scientific.net/amm.110-116.639.

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The paper presents the results of an investigation on aluminum-silicon (LM6) alloy using pressurized lost foam casting process. The study investigated the effect of pressure on casting integrity-geometry, eutectic silicon spacing, particle roundness and hardness. Following air pressures: 1bar, 2bar, 3bar and 4bar were applied on the solidifying alloy. The eutectic silicon spacing and particle roundness were measured using optical microscope which was equipped with image analyzer by averaging of at least ten results as well as Vickers hardness testing machine. For casting integrity-geometry all surfaces of solidified castings were captured by digital camera for better observation. The results show that applying pressure during solidification of the LM6 alloy has significant influence on casting integrity-geometry, eutectic silicon spacing, particle roundness and hardness of the alloy. By increasing the applied pressure, solidification time decline. Consequently, silicon spacing reduces as well as increasing of hardness. Besides, rising air pressure lead to fulfilling of molten which improves the casting integrity and particle roundness.

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36

Izman, S., Amirreza Shayganpour, M. H. Idris, and Hassan Jafari. "DOE Analysis of the Influence of Sand Size and Pouring Temperature on Porosity in LFC." Applied Mechanics and Materials 121-126 (October 2011): 2661–65. http://dx.doi.org/10.4028/www.scientific.net/amm.121-126.2661.

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Lost foam casting is a relatively new process in commercial terms and is widely used to produce defect free castings owing to its advantages like producing complex shape and acceptable surface finish. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different sand sizes and pouring temperatures on the porosity of thin-wall castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section of casting. Finer sand size is more favourable than coarse size for LFC mould making process.

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37

Acimovic-Pavlovic, Zagorka, Milutin Djuricic, Sasa Drmanic, and Rade Djuricic. "The influence of the parameters of lost foam process on the quality of aluminum alloys castings." Chemical Industry 64, no. 2 (2010): 121–27. http://dx.doi.org/10.2298/hemind100301011a.

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This paper presents the research results of application of Lost foam process for aluminum alloys castings of a simple geometry. The process characteristic is that patterns and gating of moulds, made of polymers, stay in the mould till the liquid metal inflow. In contact with the liquid metal, pattern intensely and in relatively short time decomposes and evaporates, which is accompanied by casting crystallization. As a consequence of polymer pattern decomposition and evaporation a great quantity of liquid and gaseous products are produced, which is often the cause of different types of casting errors. This paper presents the results of a research with a special consideration given to detecting and analyzing the errors of castings. In most cases the cause of these errors are defects of polymer materials used for evaporable patterns production, as well as defects of materials for refractory coatings production for polymer patterns. The researches have shown that different types of coatings determine properties of the obtained castings. Also, the critical processing parameters (polymer pattern density, casting temperature, permeability of refractory coating and sand, construction of patterns and gating of moulds) significantly affect on castings quality. During the research a special consideration was given to control and optimization of these parameters with the goal of achieving applicable castings properties. The study of surface and internal error of castings was performed systematically in order to carry out preventive measures to avoid errors and minimize production costs. In order to achieve qualitative and profitable castings production by the method of Lost foam it is necessary to reach the balance in the system: evaporable polymer pattern - liquid metal - refractory coating - sandy cast in the phase of metal inflow, decomposition and evaporation of polymer pattern, formation and solidification of castings. By optimizing the processing parameters castings of required structural and mechanical characteristics could be achieved, casting defects characteristic for this process could be avoided with the result of the production costs saving. The presented results can be useful to define parameters of Lost foam process and its application in practice with objective to obtain castings with in advance specified quality.

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Izman, S., Amirreza Shayganpour, and M. H. Idris. "Effect of Casting Parameters on Porosity in LFC." Applied Mechanics and Materials 148-149 (December 2011): 1198–201. http://dx.doi.org/10.4028/www.scientific.net/amm.148-149.1198.

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Cast aluminium alloys often contain microstructural defects resulting from the casting process such as porosity. Developments of Lost foam casting (LFC) process is considered as one of the most rapid in casting technology owing to its unique advantages on energy savings and capabilities to produce castings with thin sections. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different pouring temperatures, slurry viscosities, vibration times and sand sizes on the porosity of castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section and finer sand size is more favourable than coarse size for LFC mould making process.

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Yang, Shu Heng, and Xiao Ming Du. "The Lost Foam Casting Simulation of the Gray Cast Iron Linner." Advanced Materials Research 834-836 (October 2013): 1580–83. http://dx.doi.org/10.4028/www.scientific.net/amr.834-836.1580.

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The lost foam casting process of gray cast iron linner was simulated in this paper by using the numerical simulation method to study the properties of the filling and solidification for lost foam casting. And the comparison of the simulated results with the practical casting obtained from foundry was implemented. The results show that the reasonable technical parameters were obtained: pouring temperature of 1400°C, foam density of 13 kg/m3, vacuum of 0.04MPa, coating thickness of 0.5 mm and coating permeability of 9.5×10-9m2/Pa·s.

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Znamenskii, L. G., O. V. Ivochkina, and A. S. Varlamov. "Lost Foam Casting with the Use of Recycling and Nanostructured Materials." Solid State Phenomena 265 (September 2017): 1016–19. http://dx.doi.org/10.4028/www.scientific.net/ssp.265.1016.

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A relevant technology issue in lost foam casting is preventing the metal penetration appearance on steel and cast-iron mouldings. As a result of the research the appropriate parting model paint compositions with the use of recycling and nanostructured materials were developed. The basic technological characteristics of the developed parting model paint compositions are: relative stickiness due to VZ-6 18...25 s; residual moisture content 1...1.5 %, permeability to gases 40...50 ea. The parting paint effectiveness is determined by defect reduction of the castings on the core blow, uncertainty in geometry, metal penetration, and also the use of available and environmentally friendly molding materials in their composition, that makes the product to be highly competitive.

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Trumbulovic, Ljiljana, Zvonko Gulisija, Zagorka Acimovic-Pavlovic, and Lj Andric. "Influence of the cordierite lining on the lost foam casting process." Journal of Mining and Metallurgy, Section B: Metallurgy 39, no. 3-4 (2003): 475–87. http://dx.doi.org/10.2298/jmmb0304475t.

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This paper discuss the influence of the refractory cordierite lining on the structure and mechanical properties of Al-Si and Al-Cu casings obtained from the Lost foam casting process. So far there has not been any report of the research on cordierite lining in the literature and moreover the cordierite ceramics have never been used in foundries. In the light of these facts this paper investigates the possibility of using cordierite for manufacturing evaporable model refractory linings. Our results indicate that the application of cordierite ceramics is comparable to talc-based refractory linings in both Al-Cu and Al-Si castings, while cordierites are favorable in Al-Cu case due to their higher melting temperature.

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Chen, Zhi Lan, and Ren Wei Yang. "Numerical Simulation of Lost Foam Casting in Special-Shaped Stainless Steel Stirrer." Applied Mechanics and Materials 101-102 (September 2011): 479–83. http://dx.doi.org/10.4028/www.scientific.net/amm.101-102.479.

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The filling process, solidification process, gasification process and node temperature change of special-shaped stainless steel stirrer via lost foam casting was simulated and analyzed by using ProCAST numerical simulation techniques. The results show that the filling and foam gasification process of stainless steel stirrer casting is a top-down, from the middle layers of outward promotion process. In the filling process, foam pattern gasification and decomposition appeared to be exacerbated by heat transfer in the whole casting. Through the node temperature change over time, it can be conformed to the principles of the order of solidification in the entire stirrer casting solidification process.

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Sulaiman, Shamsuddin, M. K. A. M. Ariffin, S. H. Tang, and A. Saleh. "Influence of Pattern Coating Thickness on Porosity and Mechanical Properties of Lost Foam Casting of Al-Si (LM6) Alloy." Applied Mechanics and Materials 300-301 (February 2013): 1281–84. http://dx.doi.org/10.4028/www.scientific.net/amm.300-301.1281.

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The combination of Aluminum alloy with lost foam casting (LFC) process is best applied in automotive industry to replace steel components in order to achieve light weight components for reducing fuel consumption and to protect the environment. The LFC process involves process parameters such as the degree of vacuum, foam degradation, expanded polystyrene (EPS) foam density, permeability of foam pattern coatings, pouring temperature, filling velocity, cooling rate, and pressure. The effect of polystyrene foam pattern coating thickness on the porosity and mechanical properties of Aluminum Al-Si LM6 alloy were evaluated experimentally. The coating thickness was controlled by slurry viscosity at range between 18sec to 20sec using Zahn viscosity cup No.5 and the foam pattern was coated up to fifth layer. Aluminum Al-Si (LM6) molten metal was poured into expandable mould and castings were examined to determine porosity distribution, mechanical properties and microscopic observation. Results from X-ray testing reveal the porosity distribution on Aluminum Al-Si LM6 castings is greater at thicker foam pattern coating sample. Meanwhile, the tensile strength of casting decreases when foam pattern coating thickness increases. Microscope observation portray the present of porosity on the casting which shows more gas defects present at thicker foam pattern coating sample. The source of porosity in LFC process is due to air entrainment or the entraining gases from polystyrene foam decomposition during pouring of molten metal. As a conclusion, mechanical strength has inverse relationship with porosity.

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Mirbagheri, S. M. H., H. Ashuri, N. Varahram, and P. Davami. "Simulation of mould filling in lost foam casting process." International Journal of Cast Metals Research 16, no. 6 (December 2003): 554–65. http://dx.doi.org/10.1080/13640461.2003.11819635.

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Matson, Douglas M., Rakesh Venkatesh, and Scott Biederman. "Expanded Polystyrene Lost Foam Casting—Modeling Bead Steaming Operations." Journal of Manufacturing Science and Engineering 129, no. 2 (September 13, 2006): 425–34. http://dx.doi.org/10.1115/1.2540608.

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The retention of pattern voids observed in the production of expandable polystyrene patterns for lost foam casting can be traced to conditions developed during mold filling and subsequent steaming. Void formation and closure, or healing, was observed using high-speed video imaging through a clear acrylic sheet cut to match one-half of a test pattern mold. Two processing conditions, i.e., the initial bead packing density and the velocity of steam as it passes between beads, were shown to significantly impact the ability of a void to heal during steaming. A model is proposed to predict conditions where voids will heal based on three criteria that relate to a limitation of the processing window, the void size, and the ability of the bead to swell.

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Fan, Z. T., and S. Ji. "Low pressure lost foam process for casting magnesium alloys." Materials Science and Technology 21, no. 6 (June 2005): 727–34. http://dx.doi.org/10.1179/174328405x43199.

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Abdelrahman, Mohamed, Jeanison Pradeep Arulanantham, Ralph Dinwiddie, Graham Walford, and Fred Vondra. "Monitoring metal-fill in a lost foam casting process." ISA Transactions 45, no. 4 (October 2006): 459–75. http://dx.doi.org/10.1016/s0019-0578(07)60225-0.

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Chang, Ann-Shing, and Teng-Shih Shih. "Permeability of coating in the lost foam casting process." International Journal of Cast Metals Research 12, no. 4 (January 2000): 263–75. http://dx.doi.org/10.1080/13640461.2000.11819363.

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Sun, Shu Li, Xin Jie Wang, Qi Qiu, Kai Jie Song, and Jun Zhang. "Lost Foam Casting Coating in Production of Cylinder Block." Advanced Materials Research 502 (April 2012): 325–29. http://dx.doi.org/10.4028/www.scientific.net/amr.502.325.

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This paper introduces the application of EPC process to the inline-four diesel engine cylinder block production. It includes the make and assembles of foam shape mould, mould design, the choice of sand and modeling, and the design of gating system, etc.

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Khodai, M., and N. Parvin. "Pressure measurement and some observation in lost foam casting." Journal of Materials Processing Technology 206, no. 1-3 (September 2008): 1–6. http://dx.doi.org/10.1016/j.jmatprotec.2007.11.309.

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