Lost Foam Casting Steps Presentation by Karel Cermak - Cermak Engineering (English Version)

1. LOST FOAM
PROCESS CHAIN

2. Raw material with blowing agent
Preexpansion Steam heat applied
Moulding EPS expanded factor ca. 30
Density control critical
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

3. EPS beads filled into Al tool
Preexpansion Steam heated to expand and fuse
Moulding Cooled to avoid distorsion
Automatic removal
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

4. Controlled shrinkage
Preexpansion Accelerated processing
Moulding Repeatability
0,2
Stabilisation 0,1
0
Glueing -0,1
0 100 200 300 400
Coating -0,2
With Stabilisation Oven
-0,3 Without Stabilisation Oven
Drying -0,4
-0,5
Cluster Insertion time (mins)
Sand Fill
Compaction
Metal Pouring
Extraction

5. Preexpansion
Hot melt glue
Moulding Short “open time”
Repeatability
Stabilisation Accuracy
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

6. Preexpansion
Moulding Coating developed for lost foam
Repeatability
Stabilisation Ceramic slurry
Glueing Precise viscosity/solids
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

7. Preexpansion
Moulding Removal of all moisture
Temperature/humidity controlled
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

8. Preexpansion
Moulding
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

9. Preexpansion
Dry unbonded sand
Moulding Rain-fill
Stabilisation Uniform
Rate controllable
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

10. Preexpansion
Moulding
Stabilisation
Glueing
Coating
Fluidisation - Compaction
Drying Precise control
Cluster Insertion
Sand Fill Vibration Analysis
5,0 5
FFT Analysis
4
Compaction 2,5
3
0,0 2
Metal Pouring -2,5
1
0
-5,0 -1
Extraction
0 25 50 75 100 0 25 50 75 100
ms Hz

11. EPS liquified and volatised
Preexpansion Metal replaces foam
Moulding All details reproduced
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

12. No shakeout
Preexpansion Sand dry and loose
Moulding Sand easily recycled
Stabilisation
Glueing
Coating
Drying
Cluster Insertion
Sand Fill
Compaction
Metal Pouring
Extraction

13. VULCAN ENGINEERING´S
EXPERIENCE & EXPERTISE
WAS INSTRUMENTAL TO
SUCCESS OF MOST
OPERATING LOST FOAM
FOUNDRIES TODAY.