contact@sydensen.com

The process sequence

Views: 19     Author: Site Editor     Publish Time: 2020-09-29      Origin: Site

From the pattern to the ready component

The Lost Foam casting process is divided into three phases:
A) The making of a polymer foam pattern
B) The coating of the pattern
C) The casting process resulting in the ready component




diagramlfc1

Phase A: Making of the pattern

During the pre-expansion (1), the raw material beads for the pattern are first of all expanded to the 30-fold of their original size. This lowers the material density to 18-25 g/l. This low density is necessary in the casting process to ensure that the molten metal added can completely and thoroughly replace the pattern. As the pre-expansion process destabilizes the beads, stability is restored in a following pressure equalization process.


The gluing (3) of simple pattern sections to one complex pattern concludes the production of the raw pattern. This step equips the LF casting process with a decisive advantage: As the multi-section pattern can be more complex than a single molding tool, the LF casting process enables the burrless production of components with undercuts and fine ducts.

diagramlfc2

Phase B: Coating of the pattern

The Cluster (4) is formed by the mounting of several patterns on a gating system. In that way, several components at once can be produced in only one casting process.

A refractory, gas-permeable coating (5) is applied to the cluster by dipping. This stabilizes the cluster and enables the evaporation of the combusted pattern during the casting process.

diagramlfc3

Phase C: The casting process

During the molding (6) process, the cluster is embedded in binderless molding sand (mostly quartz sand) in a casting flask. Vibrations ensure that the material is compacted and cavities and undercuts are filled.

During the casting (7) process, the molten metal added through the gating system decomposes the polymer foam pattern and replaces it down to the last detail.

The separation of the resulting components from the molding material, the demolding (8), is especially simple in the LF casting process. The molding material is dumped from the flask and thus reveals the ready cast parts




During the molding process (2), the individual parts of the final component pattern are produced. Therefore, a molding tool made of aluminium is filled with the pre-expanded beads. Added steam ensures that the poly-styrene beads are welded together. A stable pattern section is formed.

In rapid prototyping, this step is omitted as the pattern is milled from one polymer foam block here.





  • Q Are you a manufacturer or a trader?

    A
    We have our own foundry ,forging factory and machinery shop located in Liaoning Province, China.
  • Q What can you do for customer?

    A
    One Stop Service
    1).Manufacturing and supply various machinery parts.
    2). Technical analysis and design 
    3).Factory audit, on-site production supervision, in-time feedback, pre-shipment quality inspection
  • Q How could you commit the product quality?

    A
    1) all our factories were ISO certified. 
    2) more than 50% of New Densen’s products were sold to worldwide top 500 companies 
    which located in North American, Western Europe, and Japan.
    3) New Densen’s QC engineers will do on-site supervision and before EX-work quality inspection. New Densen will issue inspection reports for customers’ approval before EX-work. New Densen will be responsible for its reports and every parts no matter how long sold to customers.
  • Q How long shall we get the quotation?

    A
    Processing time for inquiry: 1-3 working days.
  • Q What's the process of developing a new steel casting product?

    A
    The procedure for new project develop as below:
    1. Technical department analyze the drawings all details 
     
    2.Pattern design and manufacture
     
    3.Casting Process
     
    4.Quality Control inspect the casting parts
     
    5.Issue inspection report for customer to check quality
     
    6. After inspection report approved, Logistics Department help arrange the shipping to customer