Sand Casting and Lost Foam Metal Casting Process


Process comparison between sand casting and foamcast®

Stage	Process description	Sand casting	foamcast®

1	Pattern making	Required	Mfg. of Tool
2	Core box making	Required	Not Required
3	Preparing risers & runners	Required	Not Required
4	Inspection of pattern	Required	Tool Insp.
5	Pattern molding	Required	Foam Molding
6	Core making	Required	Not Required
7	Painting	Required	Not Required
8	Assembly of mold and core	Required	Ass. Of Risers
9	Pouring	Required	Required
10	Knock-out	Required	Not Required
11	Rejection post Knock-out	Approx 10%	0% - NO REJECION
12	Shot blasting of casting	Required	Not Required
13	Riser cutting	Required	Required
14	Heat treatment	Required	Required
15	Shot blasting	Required	Required
16	Fettling / finishing	Required	20% of sand casting
17	Casting finish / quality (visual) Check Ra:	300 - 600 μin	16 - 125 μin
18	Post finish rejection	Approx 2%	0% - NO REJECION
19	Check major salvaging	Required	Not Required
20	Check for minor salvaging	Required	Not Required
21	Inspection (dimentional /NDT)	Required	Required
22	Check if salvaging of casting possible	Required	Not Required
23	Machining	Required	Required
24	Rejection post machining due to defects	Approx 2%	0% - NO REJECION
25	Check if salvaging of casting possible	Required	Not Required
26	Assembly	Required	Required

1. From the above Table it is clear that foamcast® reduces the number of process stages from 26 to just 12 stages.
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