China Aluminum Industry: Lost Foam Casting (Large Aluminum Mold Processing)
Lost foam casting is a modern and efficient method used in the aluminum industry for producing complex and precise castings. The process begins with the creation of a foam model based on EPC (Expansible Pattern Casting) technology. This model is coated with a special refractory paint, dried, and then placed into a specialized sand box. Dry sand is filled around the model, and the entire assembly is subjected to three-dimensional vibration to ensure proper compaction. A vacuum is then applied to facilitate the casting process. As the metal is poured into the mold, the foam model vaporizes, leaving behind a cavity that is filled by the molten metal, resulting in a casting that exactly matches the original foam pattern. Once the metal has solidified, the vacuum is released, and the sand is removed, allowing the casting to be extracted and the cycle to repeat.
1. Manufacturing foam gasification molds using manual or mechanical methods;
2. Drying the foam molds after they are assembled;
3. Applying a refractory coating to the surface of the foam mold and drying it thoroughly;
4. Placing the mold into a special sand box and securing it on a three-dimensional vibration table;
5. Filling the box with dry sand and vibrating it to ensure even distribution;
6. Positioning the dried foam mold at the bottom of the sand box, dividing the sand as required, and automatically smoothing the top after a certain period;
7. Covering the sand box with a plastic film, placing a pouring cup, and applying negative pressure through a vacuum system. Once compacted, molten metal is poured in, causing the foam to vaporize and the metal to take its place;
8. After the casting has cooled and solidified, the vacuum is released, the sand box is turned over, and the casting is carefully removed for further processing.
The Nanjing Transit Large Mold Processing Center specializes in lost foam casting and large aluminum mold manufacturing. With advanced bubble plastic mold technology, we can design and produce molds according to your specific requirements. Our process ensures high precision, efficiency, and convenience, making us a trusted partner for your mold casting needs.
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