Lost-foam

Dr. Suyitno, ST., M.Sc.

Lost-foam
! tiny polystyrene beads, which are subjected to heat and vacuum to release the pentane gas stored in the raw beads. At this step, the beads are expanded to nearly 10 times their original size.

Lost-foam
! The pre-expanded beads are transferred to injection machines and blown into molds. Steam is used to expand the beads further and fuse them together, forming the pattern.

Lost-foam
! Patterns waiting to be assembled

Lost-foam
! After the patterns age, individual pattern sections are loaded into an assembly machine, accurately positioned for selective application of adhesive and glued together

Lost-foam
! Cluster assemblies are dipped in a water-based ceramic coating material.

Lost-foam
! After drying, the coated cluster is mechanically inserted into a pouring box that contains a fluidized bed of dry, unbonded sand. Vibrating packs the dry sand tightly around the cluster assembly

Lost-foam
! Molten metal is automatically poured into the patterns, displacing the foam and forming the casting.

Lost-foam
! After a short cooling period, the casting cluster is removed from the pouring box.

Lost-foam
! The casting cluster is water-quenched to remove the majority of the ceramic coating and improve mechanical properties.

Lost-foam
! The castings are degated, cleaned and T-5 heat treated, then go to machining and are leak tested.

Lost-foam
! Finally, castings are inspected and packed for shipment.