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The foam pattern, typically made from polystyrene, is coated with a refractory material and then buried in sand. When molten metal is poured into the mold, the foam vaporizes, leaving behind a cavity that is filled by the metal, thus forming the final cast part.
It is similar to investment casting except foam is used for the pattern instead of wax. This process takes advantage of the low boiling point of polymer foams to simplify the investment casting process by removing the need to melt the wax out of the mold.
EPC process, also known as full mold casting, is a new casting method that uses foamed plastics (such as EPS, STMMA or EPMMA) to make molds, and forms castings by pouring liquid metal. Lost foam casting is widely used in the production of various complex castings such as automotive parts, engineering machinery components, pipelines and valves, agricultural machinery components, etc.
Grey cast iron: HT150, HT200, HT250, HT300
Ductile iron: QT350, QT400, QT450, QT500, QT550, QT600, QT700, QT800, QT900
Cast steel: ZG200-400 (ZG20, ZG25, ZG35, ZG45 ,ZG55), ZG270-500 (ZG30, ZG35, ZG40Mn ZG45Mn), ZG30MnSi, ZG35MnSi, ZG20CrMo, ZG15Cr1Mo1V.
Stainless steel: ASTM
A351: CF3, CF8, CF3M, CF8M, CF8C, CF10M, CN7M, CG3M, CG8M, CN3MN, CK3MCuN;
ASTM A747: CB7Cu-1;
EN10213: 1.4308, 1.4408, 1.4581;
RCC-M M3402: Z3CND19-10M, Z3CN20-09M.
Cast copper: ZCuZn16Si4, ZCuZn40Mn3Fe1, ZCuZn40Mn2, ZCuSn5Pb5Zn5, ZCuAl10Fe3Mn2, etc.
Cast aluminum: ADC12, A380, A356, AlSi10Mg, etc.
Lost foam casting has the following advantages:
1. High Precision:
Foam plastic models ensure accurate dimensions and smooth surfaces. Without parting lines and cores, it effectively reduces dimensional deviations and surface flaws, guaranteeing high-quality castings.
2. Design Flexibility:
Multiple parts can be integrated into one model for casting, optimizing part structures and reducing assembly work.
3. High Efficiency:
Eliminating complex procedures like mold removal and core setting shortens the production cycle, making it suitable for mass production.
4. Cost-effective:
Reducing tooling use and simplifying processes cut down on equipment and labor costs.
5. Wide Applicability:
It can produce various - material castings with complex shapes, especially those challenging for traditional methods.
Lost foam casting reduces material waste and boosts efficiency for several reasons. Firstly, it uses foam plastic patterns that vaporize completely during pouring. There's no need for large machining allowances to compensate for defects, thus saving metal materials. Also, without the use of sand cores, the waste of such auxiliary materials is avoided.
Secondly, the process streamlines production. It skips complex steps like pattern removal, core setting, and mold closing, cutting down time consumption and human errors. Moreover, multiple patterns can be placed in one sand box for casting, and the reusable molds cut down on mold-making time and cost, enhancing overall efficiency.
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