No Bake Process and foamcast

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

For more information click:
Sand Casting and foamcast
Green Sand versus foamcast
Lost Wax Process versus foamcast
Equipments Required for the foamcast Process