Lost Foam Casting Parts

Support custom orders with images

Lost foam casting parts are machine components produced through the lost foam casting process.The lost foam casting process uses expandable polystyrene beads as the model material,which are made into patterns through processes such as pre casting,curing,and molding.After being coated with refractory coating and dried,they are then molded in dry sand.Fill dry sand around the shape and compact it before pouring.

The manufacturing process of lost foam casting parts is a complex and intricate process that involves multiple key steps to maintain product quality and performance.The following is a detailed analysis of the process flow:

1、Preliminary preparation

Design and drafting:Conduct detailed design and drafting work based on the requirements and performance requirements of machine tool castings.This includes determining the shape,size,material,and necessary process parameters of the casting.

2、Foam plastic model production

Pre foaming:EPS beads are pre foamed to obtain a foam pattern with low density,smooth surface and good quality.This step usually involves preheating,feeding,stirring,vacuuming,spraying water mist,stopping vacuuming,and discharging.

Maturity:Leave the pre foamed beads for a few hours to mature,allowing air to enter the beads and increase their dryness and elasticity.The maturation time is generally determined according to specific process requirements.

Molding:Fill the matured beads into the mold and shape them into the same shape as the desired casting through heating and pressure.The molding process requires strict control of parameters such as temperature,pressure,and time.

3、Model processing

Drying:Dry the molded foam plastic model to remove residual moisture and enhance its stability.The drying temperature and time need to be determined according to the material and process requirements of the model.

Combination and bonding:For complex models,it may be necessary to divide them into blocks before combining and bonding them.This requires the use of specific adhesives to ensure the integrity and stability of the model.

4、Coating hanging and drying

Coating application:Brush,spray or dip a layer of refractory coating on the surface of the foam plastic model.The main function of coatings is to prevent metal liquid from penetrating the model and protect the model from damage during the pouring process.At the same time,coatings can also improve the strength and stiffness of the model.

Drying:Dry the model coated with paint to ensure that the paint is dry and adheres to the surface of the model.The drying temperature and time need to be determined according to the type of coating and process requirements.

5、Styling and Casting

Styling:Place the dried model in a specially designed sand box and fill it with dry sand for shaping.By vibration or compaction,dry sand is tightly wrapped around the model to form a cavity.

Pouring:Pour molten metal into the mold cavity through a pouring cup.During the pouring process,the molten metal will rapidly vaporize the model and fill its position.The pouring temperature and speed need to be determined according to the type of metal and casting requirements.

6、Post processing

Cooling and solidification:The poured metal liquid cools and solidifies into castings in the mold cavity.The cooling rate and time need to be determined according to the type of metal and casting requirements.

Cleaning and trimming:After the casting solidifies,it is necessary to clean the surface of sand particles and impurities,and carry out necessary trimming work to meet the requirements of use.

Heat treatment and testing:Heat treat the castings as needed to change their properties,and conduct quality testing to ensure that the castings meet relevant standards and requirements.