Lost Foam – an advantageous casting process

Lost foam cast part with attached foam pattern

Lost foam cast part with attached foam pattern

Lost foam cast part with attached foam pattern

Lost foam cast part with attached foam pattern



Lost foam is a modern production process for the manufacturing of cast metallic parts with demanding geometry. The use of vaporisable foam patterns in a mould that is free of parting lines enables burr-free and dimensionally-accurate castings with excellent surface quality. GSL is unique worldwide in having 20 years of experience in the manufacturing of cast steel parts using this process.

Process principle
The use of foam models is typical for the lost foam casting process. They are clustered with a filling system, then covered with a thin ceramic layer, and finally moulded into a bonding-free moulding material. During the pouring, the flowing hot melted steel vaporises the foam pattern and at the same time precisely fills the resulting hollow space. In this way, an exact metallic copy of the foam pattern is created. At the same time, a vacuum placed on the moulding material ensures sufficient mould stability, as well as the complete extraction of the combustion products from the foam model material. The post-combustion of the extracted casting gases leads to an almost emission-free casting process, with low energy demands and closed circulation of the mould material, free of bonding agents.

Advantages

  • Suitable for complex part geometries
  • Integration of multiple parts into one cast part possible without casting-typical undercut problems
  • "Near-net-shape" casting with low machining allowance
  • Holes, slits, breaking through of walls and complex internal geometry can be implemented
  • Burr-free cast parts with excellent reproduction of pattern details and superior surface quality
  • Suitable for thin-walled light-weight construction
  • Economical and environmentally-friendly casting process

Product characteristics

  • Wall thicknesses can be cast from 3 mm
  • Tolerances in accordance with ISO 8062 CT07 - CT09
  • Surface quality Ra 6.3 and better

Application area

  • Demanding part geometries
  • Serial sizes min. 500 - 1000 items/a for serial casting with foam models
  • Single casting or small series with milled or built patterns
  • Part size max. 600 x 600 x 600 mm
  • Part weight 1 - 100 kg
  • Materials: all cast steel types with  > 0.1 % carbon content





GussStahl Lienen GmbH & Co. KG

Industriestraße 10
D-49536 Lienen

Fon: +49 (0)5483/7454-0
Fax: +49 (0)5483/7454-54

info@gsl-lienen.de

GussStahl Lienen GmbH & Co. KG

Industriestraße 10
D-49536 Lienen

Fon: +49 (0)5483/7454-0
Fax: +49 (0)5483/7454-54

info@gsl-lienen.de

GussStahl Lienen GmbH & Co. KG

Industriestraße 10
D-49536 Lienen

Fon: +49 (0)5483/7454-0
Fax: +49 (0)5483/7454-54

info@gsl-lienen.de