ISSN (1897-3310)

ARCHIVES Volume 9
Issue 2/2009
of 143-146

FOUNDRY ENGINEERING 32/2

Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences

The lost foam process in pilot castings plattes

Z. ĩóákiewicz1, M. ĩóákiewicz1
1
Instytut Odlewnictwa, ul. ZakopiaĔska 73, 31 418 Kraków, Polska
1
kzs@iod.krakow.pl

Recieved 26.02.2009; accepted in revised form: 30.03.2009

Abstract
The paper discusses the process of thermal evaporation of a foundry pattern. At several research-development centres, studies have been
carried out to examine the physico-chemical phenomena that take place in foundry mould filled with polystyrene pattern when it is poured
with molten metal. In the technique of evaporative patterns, the process of mould filling with molten metal (the said mould holding inside
a polystyrene pattern) is interrelated with the process of thermal decomposition of this pattern. The process of polystyrene pattern
evaporation in foundry mould under the effect of molten metal is of a very complex nature and depends on many different factors, still not
fully investigated. The technology of evaporative patterns was used in manufacture of pilot castings of the high abrasion resistance plates.
The material and the properties of the resultant castings were determined by the customer (patent protection). At the beginning of the
studies, the properties of the pattern material were determined, patterns were assembled, the properties of the ceramic layer were
determined as well as the technique of its preparation and application. The technique of molten metal feeding to the mould cavity was
examined along with the parameters of the gating and feeding system, and casting cooling and solidification conditions (large contraction,
shrinkage cavities and depressions).

Keywords: Lost foam platetes, Pattern, Polystyrene, Temperature.

1. Introduction 2. Preparation of the mould,

The technology of foamed polystyrene patterns thermally
evaporated during manufacture of castings from ferrous alloys
still finds numerous obstacles on the way to its full practical use.
The degree of difficulty depends not only on the properties of the
process itself, but also on the degree of pattern intricacy, mould
properties, and quality requirements imposed on castings. One of
the main parameters which decide about the correct run of the
evaporative pattern process is the kinetics of the thermal
decomposition of the foamed polystyrene pattern as well as the
volume and pressure of gases which are evolving from this
pattern. Casting using the lost foam method is used when small
quantities of abrasion-resistant castings must be rapidly produced
at low cost. This method was suggested as a feasible alternative
for classical methods involving moulding sands.
These elements must be characterized by high hardness (above 60
HRC) and high abrasion resistance.
This article presents the results of the Lost Foam process in pilot
castings plattes.
permeability
The moulds were prepared according to common praxis
applied in the Foundry research Institute, i.e. a ceramic layer of
proper thickness was deposited onto the foamed polystyrene -
copolymer model (fig. 1). The model assembly with ceramic layer
was moulded in dry unbounded quartz sand of defined granularity
(fig. 2 - 3), [10, 14 -17].
The ceramic layer was made using ceramic coating materials:
x Kerrntop L87 – manufactured by Ashland, solid phase 74-
77%, density 2.26-2.38g/cm3, viscosity 6.8-10.0 Pa·s;
x Troflex WK-LF, solid phase 83-84%, viscosity 30,0 Pa·s;
density 2.6 g/cm3 – produced by Ashland,
The number of ceramic layers – 1, its thickness does not exceed
0.7 mm (fig. 2).
The self-supporting mould made of ceramic layers the
technology and materials used were developed in The Enterprise
of Foundry Innovation, Ltd:

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x Ceramic layers were prepared according to technology
usually applied in lost-wax process, with four ceramic layers.
Drying and/or baking of ceramically-covered sets of models were
carried out according to procedures developed in Foundry
Research Institute.
Fig. 1. Foamed polystyrene model
Fig. 2. Foamed polystyrene pattern coated with ceramic layers
For preparation of moulds the mould cavity for lost foam
process has been used. This mould cavity comprises of special
moulding flasks, stand for preparation of model sets (formation of
ceramic coatings, consolidation, preparation for mould pouring).
Assumptions:
x the number of model sets in the moulding flask,
x mould material – coarse quartz sand from Jaworzno,
Preparation of model sets:
144 A R C H I V E S O F F O U N D R Y E N G I N E E R I N G Vo l u m e 9 , I s s u e 2 / 2 0 0 9 , 1 4 3 - 1 4 6
™ sand pouring into the moulding flask,
™ positioning of the model sets and pouring with sand,
™ vibrational consolidation.
The moulds were subjected to thorough inspection and directed to
the pouring stand.
The technological detains of mould preparation, melting
parameters and pouring procedure were developed in the Foundry
Research Institute.
Fig. 3. Foamed polystyrene pattern coated with ceramic layers
3. Attempts of fabrication of
experimental cast plates from highly
alloyed materials
Test plates of highly alloyed iron alloys were prepared
during realization of the research project. For further
investigations were chosen plates of assumed chemical
composition.
Mould technology, parameters of melting and pouring were
developed in the Foundry Research Institute, [1-4, 6, 7, 10 -17].
The chemical composition of alloys was developed by the
authors of this presentation within their research activities at
Department of Metal Sciences and Powder Metallurgy (AGH
University of Science and Technology) and Department of
Ferrous Alloys (Foundry Research Institute). Three different sorts
of alloys were selected for experimental works. The charge
material contained iron alloys, alloy additives, pure elements, and
carbonizing additives of predefined granularity.
The melting process was conducted in medium frequency
inductive furnace of 60 kg capacity.
The superheating and casting temperatures of the molten
metallic materials were determined. It contained within 1550oC –
1600oC (fig. 4, 6).
 Fig.7. Fracture of the casting

Fig. 4. Polystyrene cast from plotted with ceramic layer Table 1. Hardness of the castings after thermal treatment

Hardness
No. of the before the Hardness after the
melting treatment, treatment, HRC
HRC
1A 53,5 68,5
1E 64 66,7
2A 47 47,5
2C 48 49
3A 30 41
3B 53,5 68,5

4. Summary
Fig. 5. Castig of the plattes In the course of experimental investigation numerous test
casting were fabricated. Thus developed technology was verified
during the progress of the project. The pouring protocol and
technological parameters have been modified. Cast plates of
satisfactory shape representation and good hardness were
obtained (fig. 5 - 7).
Some of the test castings were subjected detailed structural
investigations and thermal processing.

Acknowledgments
The article came into being in support about results of
investigations led At Foundry Research Institut. The thanks the
executors of described project

Fig. 6. Casting References

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