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Lost Foam Metal Casting Technology by Jayshree Machines And Tools
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  • Chinese V LFC Versus Foamcast
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  • No Bake and Foamcast
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No Bake Versus foamcast Lost Foam Metal Casting Technology

Process Steps involved in foamcast
Pre-formed EPS bead fead in Pattern Mold. = EPS bead Rate Rs.95.0/kg
Density of EPS Pattern, 45Kg/cu.mt.
1.0kg of Molded EPS equivalent to 185kgs of cast steel
EPS rate per kg of casting Rs.0.515
EPS Feeding Cycle Time approx. 1.5 - 2 mins
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Assembly of EPS Patterns = Approx. time 15 minutes per pattern cluster
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a. Slurry Prime Coat followed by stucco & then Dried
b. Slurry back-up Coat followed by stucco & then Dried
= Ceramic Coatings Rs. 50.0/kg
Shell to metal Ratio 0.08:1 with a 65% yield
Shell cost Rs. 7.15/kg of finished casting 
Approximate Cycle Time - 4 Hours
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Drying of Coated Pattern/Cluster = 3 Hours
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Burn-Off of EPS Pattern & Shell Sintering = 40 Minutes
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Ash removal & quality check of Shell = 15 Minutes
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Placing Ceramic Shell at Room Temp. in Molding Box = 5 Minutes
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Metal Pouring = 1.0 Ton in 20 Minutes with assistance of 4nos. Workers
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Knock-out & Shell Removal = Thin shell requires short vibratory knockout & shot-blasting
Process Steps involved in No Bake Process:
Mix moulding sand
Mould cope and drag
Mix core sand
Mould cores
= Mixed sand = Rs. 1.5 / kg
4.5kg sand = 1.0 kg cast metal
Sand cost = Rs.18.0/kg finished casting
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Hardening of cores and molds = Approx. 25 Minutes
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Painting of Cores & Mold Cavity = Paint cost Rs.3.0/kg cast metal
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Clean mould
Set cores
Close mould
Clamp mould
= 8 molds per hour
6 man team for moulding, painting and closing
1 mold per man hour
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Metal Pouring = 1.0 Ton in 25 Minutes with assistance of 5nos. Workers
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Knock-out & finishing = Grinding wheels Rs.6.0/kg finished casting
Welding rod Rs.5.0/kg finished casting
Plus labour content to remove risers & flash

Process Video
Process Presenation
Process Cost
Equipment
V/s Sand Casting
V/s Green Sand
V/s Chinese Process
V/s Lost Wax
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