Lost Foam Casting Process

for Ferrous and Non-ferrous Foundries

need for post-casting machining.

This paper critically examines
the various aspects of lost foam
casting process.
DR ASHOK SHARMA* Key words:
*Ex- Professor, Department of Metallurgical and
Materials Engineering, MNIT Jaipur Polystyrene Foam,Refractory
Email: ashok.mnit12@[Link] Coating, Dimensional
AccuracyProcess Control
Abstract pattern that is an exact replica of
1. Introduction
Lost Foam Casting (LFC) is the desired final part. This foam
Lost foam casting (LFC) is widely
an innovative technique that pattern is then coated with a
employed in the automotive
facilitates the production of refractory ceramic material to
industry for the production of
high-yield metal castings through form a mould. Once the coating engine blocks, cylinder heads,
the evaporative decomposition dries, the foam pattern is placed and other intricate components.
of expanded polystyrene (EPS) in a flask and surrounded by It is also used in the aerospace
patterns during the pouring unbonded sand. When molten industry for manufacturing
and mould fillingprocess. This metal (either ferrous or non- lightweight, high-strength
method excels in casting intricate ferrous) is poured into the parts, and in various industrial
geometries, such as manifolds mould, the foam vaporizes applications requiring precision
and engine blocks with internal and is replaced by the metal, and performance. However, there
cavities, making it particularly capturing the shape and details is a critical need to examine the
valuable in ferrous and non- of the original foam pattern with impact of process parameters
ferrous industries requiring high reliability. The metal then on the microstructure and
complex shapes. However, the solidifies to form the final casting. mechanical properties of the
economic viability of LFC is This innovative technique offers castings, given the relative
primarily limited to high-volume several advantages. It eliminates novelty of the process. Overall,
production due to the need for the need for traditional cores, lost foam casting is a versatile
specialized tooling and moulds. simplifies the moulding process, and efficient method for
The process begins with the and produces near-net-shape manufacturing high-quality
creation of a polystyrene foam parts, significantly reducing the metal parts, offering distinct

45
advantages that have garnered adaptable and customizable This advancement allows for
significant interest from casting design capabilities, as foam better management of the
manufacturers. It is suitable for patterns can be easily produced gases generated during the
both ferrous and non-ferrous through slicing and adhesion, decomposition of the pattern,
metals, making it a versatile enabling complex designs influencing the rate at which
method across various industries. without the need for cores and the liquid metal flows within the
thereby reducing processing mould during the filling process.
The process begins with creating
time, costs, and equipment
a foam pattern that mirrors the General Motors Corporation
investment. The streamlined
final desired casting. This foam began producing aluminium alloy
manufacturing workflow further
is then coated with a refractory cylinder blocks and heads 5 in
enhances productivity by utilizing
slurry and allowed to dry. After 1985. In 1993, BMW established
a loose-sand compact method
drying, the pattern undergoes a production line capable
without binders, allowing for
compaction before molten metal of manufacturing 200,000
the reuse of sand and enabling
is poured into it. As the metal fills aluminium alloy cylinder heads
multiple castings to be poured
the cavity, the foam vaporizes, annually, achieving a 90% yield
simultaneously, making it ideal
leaving a metal casting that by 1995, with a daily output of
for mass production. Moreover,
closely resembles the original 1,500 pieces6. Other companies
LFC is environmentally friendly,
pattern1,2. LFC is known for its also set up aluminium alloy lost
minimizing emissions and
ability to produce near-net foam casting (LFC) production
achieving over 95% sand reuse,
shapes and intricate designs, lines. M. Sands and S. Shivkumar7,8
which enhances workplace
making it a valuable technology studied the fusion of bead
safety by reducing noise, carbon
in modern manufacturing. particles, finding that increased
monoxide, and silica dust
fusion improved foam pattern
LFC offers several significant exposure.
strength but also raised casting
advantages, making it a highly
efficient manufacturing process.
2. State of the Art defects due to slower metal flow.
Initially, zircon-based coatings3 M. R. Barone and D. A. Caulk9
Firstly, it provides enhanced
were employed to serve as a developed a model linking heat
dimensional accuracy and surface
barrier between the polystyrene transfer, polymer decomposition,
finish, achieving precision within
pattern and the unbonded sand and gas diffusion, correlating well
Casting Tolerance grades CT5-
mould. These early coatings with experimental data. Guillaume
CT7 and surface roughness levels
were designed to prevent Houzeaux and Ramon Codina10
of Ra 6.3-12.5 μm, comparable to
sand collapse into the cavity used finite element methods to
investment casting. This results
created by the degradation of simulate gas back pressure in
in minimal machining allowances
the pattern before it could be LFC. Sun W. L. 11 employed X-ray
of 1.5-2 mm, leading to a 40-
filled by the advancing metal detection to assess aluminium
50% reduction in mechanical
front, thereby enhancing the alloy filling, concluding that
processing time and costs
surface finish of the resulting patterns with uniform density and
compared to traditional sand
[Link] the years, coatings smooth surfaces are optimal. D. R.
casting, while also eliminating
have evolved to also function Hess 12 found that EPS bead type
flash burrs and improving
as a control mechanism for the and fusion degree significantly
overall dimensional accuracy.
escape of degradation products4. influenced metal filling [Link]
Additionally, LFC allows for

46
defect control, S. R. Shin and Z. H. through a process similar to foam as it fills the cavity. The
Lee 13
investigated hydrogen pore injection moulding, where heat from the molten metal
formation during aluminium alloy polystyrene beads are injected decomposes the foam, while
LFC. They identified that the initial into pre-heated aluminium the permeable coating allows
hydrogen concentration in molten moulds, followed by steam byproducts to escape, ensuring
metal and the reaction time with application to expand the foam smooth metal flow.
EPS affected hydrogen porosity. and fill the mould cavity. The final
5) Casting Collection:
At lower pouring temperatures, pattern comprises approximately
97.5% air and 2.5% polystyrene. Once the metal solidifies, the
hydrogen from liquid EPS
sand is removed, revealing the
entered the metal, while at higher 2) Insulation Painting:
ceramic shell that encases the
temperatures, it primarily came
After forming, the pattern is finished part. The ceramic shell
from gas and liquid products. The
coated with insulation paint, and any excess material are then
permeability of the coating also
enhancing durability and stripped away.
significantly influenced hydrogen
protecting against erosion. The
pore formation. The coated clusters in Lost
flask is designed to effectively
Foam Casting (LFC) are
3. LFC Process vent gases produced during foam
positioned in moulding flasks
Lost Foam Casting (LFC) combustion when molten metal is
using a jig, with the remaining
technology consists of five key poured.
space filled with dry sand
steps (fig-1): pattern design,
3) Placement and Support: that is compacted through
insulation painting, placement
vibration. This method has
of the pattern in a sand flask, The coated pattern is positioned
successfully produced castings
pouring of molten metal, and in a flask, surrounded by loose,
in aluminium, brass, bronze,
unbonded sand, which is
collection of castings. cast iron, and steel. For specific
compacted to provide external
1) Pattern Design: ferrous grades, polystyrene
support.
patterns can be replaced with
The pattern is made from 4) Metal Pouring: a copolymer of polystyrene
expanded polystyrene foam,
Molten metal is poured into the and polymethylmethacrylate
which is an excellent thermal
inlet pipe, igniting the polystyrene to avoid carbon film defects.
insulator and chemically resistant,
functioning effectively below
75°C. Patterns can be crafted
in various ways depending on
complexity. For detailed designs,
patterns may be assembled
from multiple foam pieces using
adhesive. Small-volume patterns
are often hand-cut or machined
from solid foam blocks, while
simple patterns can be created
using hot wire foam cutters.
Figure1: Lost foam casting (LFC) process.
Large volumes may be produced

47
 modes and their influencing
factors is crucial for optimizing
the lost foam casting process and
ensuring high-quality castings16.
Simulation models are available
for optimising casting design and
for estimation of mould filling
time17.

3.2 New Developments-Lost

Foam Casting Under Vacuum
and Low Pressure

The lost foam casting under

Figure-2: Metal cylinder valve and its foam pattern15 vacuum and low-pressure
process integrates the principles
of lost foam casting with low
This technique is valued for its to evaporate. This process can
pressure casting, effectively
simplicity and cost-effectiveness, exhibit varying behaviours,
harnessing the benefits of both
enabling the production of categorized into three modes:
methodologies18,19. The filling
intricate moulds made from foam. contact mode, gap mode, and
capability of the molten metal
The procedural steps of LFC are collapse mode. Factors such as
is significantly enhanced due to
depicted in Figure 1, while Figure the thickness of the foam, heat
the controlled pressure during
2 illustrates a final cast (such as a transfer properties of the metal,
the filling [Link] advantages
cylinder valve and its associated metal temperature, and foam
include:
head) alongside its foam mould density significantly influence
[14].To improve the quality of the length of the heat transfer a) Cost Efficiency: Compared
the final casting, it is essential gap during [Link] contact to die casting, this process
to monitor the behaviour of the mode, which is more prevalent in is more economical while
molten metal during the filling of thicker sections of the pattern, the allowing for subsequent heat
the foam pattern. This monitoring molten metal comes into direct treatment to increase the
allows for the identification contact with the foam, leading strength of the castings.
and rectification of process to immediate decomposition.
b) Dimensional Accuracy:
faults, thereby enhancing the In contrast, gap mode occurs
Castings exhibit high
consistency of the filling process when there is a space between
dimensional precision and
and reducing variations in process the metal and the foam, which
smoother surfaces than those
parameters. can affect the rate of heat
produced via sand casting.
transfer and the timing of foam
3.1 Interaction of Foam Patterns
evaporation. Collapse mode is c) Material Compatibility: The
with Molten Metal
characterized by the structural method accommodates
In the lost foam casting process, failure of the foam under the alloys with low heat content,
as molten metal flows into the heat and pressure of the molten enabling the production of
mould, the heat generated [Link] these castings using the lost foam
causes the polystyrene pattern process under counter gravity

48
 conditions.

d) Optimized Production:
The design minimizes the
running system length and
reduces heat loss prior to the
replacement of expanded
polystyrene (EPS) patterns,
resulting in efficient high-
volume production of near-
net shape castings.

e) Controlled Filling: The molten

metal is introduced under
counter gravity conditions,
maintaining good control
at low pressure, esulting in
dense castings suitable for a
variety of nonferrous alloys.

The accompanying schematic

diagram (Figure 3) illustrates the Figure-3: Schematic diagram of LFC under low pressure and vacuum [19]

layout of the lost foam casting

under vacuum and low-pressure is a process that uses 3D printing Lost Foam casting process
process. to create lightweight foam has made significant strides

The flow of metal inthe EPC patterns for lost foam casting. in precision casting for large
process is quited ifferent from The HLFC process combines and small items, especially by
that in others and casting the quality and accuracy of incorporating modern tools like
[Link] decomposition investment casting with the 3D printing and computerised
of the foam pattern toliquid and flexibility and lower cost of sand [Link] method not
then to gaseous phase retards
casting20. A novel manufacturing only enhances the feasibility
therateofmetal flow. The clue
process combining 3D printing of of producing intricate patterns
to successful exploitation of the
processlies in managing the polyactic acid foam patterns with economically but also maintains
metal flow into the mould cavity the Lost Foam Casting process high mechanical properties and
and ensuring flow of gaseous (LFC) has been developed, which dimensional accuracy, making it
products out of the mould. was applied successfully to an attractive option for various
3.3 Hybrid Lost Foam Casting produce A356 Aluminium alloy industrial applications.
(HLFC) castings.

Hybrid Lost Foam Casting (HLFC) 4.0 Conclusion

49
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