foamcast

CASTING PROCESS

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foamcast
Process Steps
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Mold foam pattern sections. Age pattern to allow dimensional shrinkage. Assemble pattern if it is a multiple piece pattern. Build cluster (multiple patterns per cluster). Coat cluster. Dry coating. Burn-off Compact cluster in flask. Pour metal. Extract cluster from flask.

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1.

Mold foam pattern sections.

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2.

Age pattern to allow dimensional shrinkage.

a. The foam material used to create the pattern shrinks in much the same manner as a typical casting. b. Patterns are aged by allowing them to rest at room temperature for a period of 5 to 7 days. c. Patterns may also be force aged in a drying oven to allow for quicker use.

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3. Assemble the Pattern

Production patterns are assembled using a precision, automated gluing machine. Glue is printed to one section of the foam and then pressed against the adjoining piece. Multiple piece parts can be built up in this way and produce very complex geometry.

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4. Clustering Glue individual patterns to sprue.

Number of patterns per sprue is dependent on part size and/or configuration.

Molded sprue is manufactured similar to foam pattern.

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5. Coating Coating parameters are verified before coating cluster. Coating is mixed continuously to maintain properties. Cluster may be hand dipped or by automated robot station.

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6. Drying & Burnoff

Coating is dried in an oven at 120 oven at 120-140F(49- 60 60C) for 3 to 5 hours. Post Drying the Pattern is put in a Furnace for Burnoff jayshree machines & tools

7. Compaction
Cluster Shell is delivered to the Flask parked on the pouring line by conveyor or by hand. The Cluster is placed into flask and held in position by a fixture or by hand. If a Fixture is used it is timed to release the cluster during the compaction cycle.

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8. Metal Pouring

Metal is poured to fill in the hollow shell. Metal may be poured by hand or with an automatic ladle.

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9. Extraction Casting is allowed to cool in sand for a predetermined period.

Sand in the Flask is then dumped on to a conveyor for recycling. Loose sand around the casting cluster helps protect the parts from damage.

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Final Casting

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Process & Cost of Production Comparison between Sand Casting and foamcast Process.
Stage 1 2 Process Description PATTERN MAKING CORE BOX MAKING Sand Casting Required Required

foamcast

Manufacture of Tool Not Required

3
4 5 6 7 8 9

PREPARING RISERS & RUNNERS

INSPECTION OF PATTERN PATTERN MOLDING CORE MAKING PAINTING ASSEMBLY OF MOLD AND CORE POURING

Required
Required Required Required Required Required Required

Not Required
Tool Inspection EPS Pattern Molding Not Required Not Required Assembly of Risers Required

10
11 12 13 14

KNOCK OUT
REJECTION SHOT BLASTING OF CASTING RISER CUTTING HEAT TREATMENT

Required
Around 10% Required Required Required

Not Required
0% Rejection Not Required Required Required

15
16 17 18 19

SHOT BLASTING
FETTLING / FINISHING CASTING FINISH / QUALITY (VISUAL) POST FINISH REJECTION CHECK MAJOR SALVAGING

Required
Required Sand Casting Around 2% Required

Required
Cost 20% of Sand Casting Investment Casting 0% Rejection Not Required

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Process & Cost of Production Comparison between Sand Casting and foamcast Process.
Stage 20 21 Process Description CHECK FOR MINOR SALVAGING INSPECTION (DIMENTIONAL /NDT) Sand Casting Required Required

foamcast
Required

Not Required

22
23 24 25 26

CHECK IF SALVAGING OF CASTING POSSIBLE

MACHINING REJECTION POST MACHINING DUE TO DEFECTS CHECK IF SALVAGING OF CASTING POSSIBLE ASSEMBLY

Required
Required Around 2% Required Required

Not Required
Required 0% Rejection Not Required Required

B. Cost Comparison: 1. From the above Table it is clear that foamcast 26 to just 12 stages.

reduces the number of process stages from

2. The saving in these process stages is equivalent to savings of around 25% cost saving over sand casting process for as cast products & over 40% for machined components

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Thank You for your valuable attention for more information on the process please dont hesitate to approach us at the counter or you can email us your queries at casting@foamcast.in or contact us on +91-98671-80179

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