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LOST FOAM CASTING PROCESS

BLUE SKY-GREEN FOUNDRY SOLUTIONS

-By GD Mishra
steel@gdmtechnics.com
LOST FOAM CASTING PROCESS-LFC

LFC for Large Castings

Pouring
Vacuum under
Flask Vacuum

No Binder
in Sand

0.5 ton to 8
ton
castings
WHY LFC FOR BIG CASTINGS
• Full Mould Process is being replaced by modern LFC process for large castings

• Large castings up to 8 tons can be cast in vacuum conditions

• Sand is scarce and foundries are polluting environment around

• Sand is without Binders and 100% recycled in LFC Process

• Vacuum helps draw EPS Fumes hence no casting problems in top section of
casting

• Production cost reduction by about 15% when compared to Full-Mould Process


WE WORK SMART
ENERGY SAVINGS IN LFC PROCESS
• Sand reclamation, the primary attrition and the secondary attrition to
achieve 75% reclamation level and the thermal attrition to achieve total
95% reclamation level needs lots electricity and gas; while the Lost
Foam Technology only needs sand cooling and recirculation.
• Because the LFC process sand does not stick to the casting surface and
there are no fins, so no energy by way of hammering, grinding and
chipping is needed for knockout and fettling of castings. Saves, time
too.
• Machining allowances of 2-5 mm at tool point so less machining
needed, saves Energy and Time.
• The overall weight of the casting is reduced needing less molten metal,
so Energy is saved.
THE MAGIC OF THE V-LFC
• Most economical moulding process for 20 kg to 350 kg castings. Any size &
shape weighing between 10-12 tons is also possible.
• A kg of EPS (Expanded Polystyrene)/STMMA (styrene methyl-methacrylate)
can produce 250-300 kg of casting.
• Intricate parts can be cast
• No Core, so no Core cost
• No Rejections due to Core Shifting
• No Fins so almost nil fettling
• Faster Delivery, Satisfied Customers, Lesser Opportunity Cost.
• Very good Surface Finish up to 200 RMS can be achieved, without big efforts;
better surface finish up to 150 RMS can also be achieved.
• Machining work minimized, 2-5 mm max at tool point.
• Sand reused with only 1% wastage max
LOST FOAM CASTING – AN OVERALL PROCESS VIDEO

470 kg each
Claw Weight
WHY WE?

• We Design your process


• We Provide you Plant Design
• We Supervise your Installation and Commissioning
• We Provide Technology Transfer and Training on Shop Floor
• We support you for Casting Development for 1 year after sales
• In foreseen cases, we can depute Chinese Expert in your foundry for 25
days
• We can even provide operational support on contract basis
LFC SAVES THE EARTH’S PRECIOUS
RESOURCES
• Reduce the amount of waste by using
less sand
Reduce • Reuse sand 99%, don’t throw
• Stop Chemical and Organic Binders

• Modernize your foundry with us


Recycle Reuse
• Less Capital than conventional foundry
system
• Less variables in the foundry by 60%
• Less Operational & Maintenance Cost
EXAMPLES OF LARGE CASTINGS BY LFC PROCESS
EXAMPLES OF LARGE CASTINGS BY LFC PROCESS
Ductile
Iron (Si-
Mo) Pellet
car for
Steel
Plant
EXAMPLES OF LARGE CASTINGS BY LFC PROCESS

Steel Stamping Die 8 ton by LFC

Steel Cylinder 6 ton by LFC for Synthetic Diamond


EXAMPLES OF LARGE CASTINGS BY LFC PROCESS
EXAMPLES OF LARGE CASTINGS BY LFC PROCESS
GENERAL DYNAMIC
MULTI-TECHNICAL CONSULTANCY LLP