China Aluminum Industry: Lost Foam Casting (Large Aluminum Mold Processing)
Lost foam casting, also known as EPC (Expanded Polystyrene Casting), is a modern and efficient method used in the production of complex aluminum castings. The process begins with the creation of a foam model according to the desired design, using either manual or mechanical techniques. Once the model is ready, it is coated with a special refractory paint, dried, and placed into a specialized sand box. The box is then filled with dry sand, and the entire assembly is subjected to three-dimensional vibration to ensure proper compaction. A vacuum system is applied, allowing the foam model to gasify and disappear during the casting process, making way for molten metal to take its place.
After the metal has solidified, the vacuum is released, and the sand is removed to reveal the finished casting. This process can be repeated multiple times, ensuring high efficiency and consistency in production.
Here's a step-by-step breakdown of the process:
1. Manufacturing of foam gasification molds (either manually or through automated systems);
2. Drying the foam mold after it has been assembled;
3. Applying a fire-resistant coating to the surface of the foam mold, followed by drying;
4. Placing the mold into a special sand box and securing it on a three-dimensional vibration table;
5. Filling the sand box with dry sand and compacting it through vibration and leveling;
6. Positioning the dried foam mold at the bottom of the sand box, dividing the sand according to the process requirements, and automatically smoothing the top of the box after a set time;
7. Covering the sand box with a plastic film, placing a sprue cup, and applying negative pressure. Once the sand is fully compacted, molten metal is poured into the mold, causing the foam to vaporize and be replaced by the liquid metal;
8. After the casting has cooled and solidified, the vacuum is released, the sand is shaken out, and the casting is retrieved for further processing or the next cycle.
The Nanjing Transit Large Mold Processing Center specializes in lost foam casting, offering high-precision aluminum mold solutions tailored to various industrial applications. With advanced technology and experienced engineers, we provide reliable and cost-effective mold casting services that meet the highest industry standards. Whether you need custom designs or mass production, our facility is your ideal partner in the aluminum casting industry.
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