Lost Foam Casting Ductile Iron Product

Ductile cast iron castings produced by lost foam casting process from China casting company.

Lost Foam Casting, also called Lost Foam Casting (LFC) or Full Mold Casting, is a kind of Evaporative Pattern Casting (EPC) with dry sand casting process. The EPC is sometimes could be short for Expendable Pattern Casting because the lost foam patterns could be used only once. After the foam patterns are finished by special machined, then the foamed plastic patterns are coated with refractory coating to form a strong shell to withstand the molten metal. The foam patterns with shells are put into the sand box, and fill it with dry sand sand around them. During pouring, the high-temperature molten metal makes the foam pattern pyrolyzed and “disappears” and occupies the exit cavity of the patterns, and finally the finished desired castings are obtained. 

The Steps of Lost Foam Casting：
1- Use foam molds to produce foam patterns and casting gating systems
2- Bond the patterns and runners to form a mold bundle module
3- Dip paint on the module
4- Dry the paint
5- Put the module into the sand box and fill it with dry sand
6- Vibrate molding in order to fill the cavity with dry sand and then compact the molding sand
7- Pouring molten metal to vaporize the foam and then forming the desired castings
8- After the castings have cooled, clean the castings. The dry sand can be recycled 

Advantages of Lost Foam Casting：
✔ Greater design freedom for complex structural castings
✔ No draft angle is needed to save lots of cost.
✔ Function integrated foam patterns could be assembled from several pieces of foam patterns.
✔ Lost foam castings are near-net-shape process
✔ High flexibility through short set-up times
✔ Longer EPS mould service lives, hence lower proportionate tool costs
✔ Assembly and treatment costs are reduced by the omission of the treatment process, installation parts, screw connections, etc.
✔ Expansion of the scope of applications 

CNC machining refers to the machining process proceed by Computerized Numberical Control (CNC for short). It is aided by the CNC to reach a high and steady accuracy with less labor cost. Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. The processes that have this common theme, controlled material removal, are today collectively known as subtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing.

Exactly what the “controlled” part of the definition implies can vary, but it almost always implies the use of machine tools (in addition to just power tools and hand tools). This is a process used to manufacture many metal products, but it can also be used on materials such as wood, plastic, ceramic, and composites. The CNC machining covers many different processes such as milling, turning, lathing, drilling, honing, grinding...etc.

Also called precision machining, the CNC machining could reach a very high accuracy in geometical tolerance and dimensional tolerance. With our CNC machines and Horizontal Machining Centers (HMC) and Vertical Machining Centers (VMC), we can almost meet all of your required tolerance grades.

Available Ferrous Metal Materials for Precision Machining Components:
• Cast Iron including gray iron and ductile iron
• Carbon Steel from low carbon steel, medium carbon steel and high carbon steel.
• Steel Alloys from standard grades to special grades on request.
• Aluminum and their alloys
• Brass and Copper
• Zinc and their alloys
• Stainless Steel, Duplex, Corrosion-resistant Steel, High-temperature Steel.

The precision machining workshop at RMC takes care probably the most important step in the supply chain after casting. State-of-the-art vertical and horizontal CNC machining centers and other CNC machines could make sure the accuracy of the castings and guarantee the machined castings are finished on time. All machines are well-organized and taken into production at high production effeciency and good cost-effective mothods. If needed, all the machined dimensions could be measured by the CMM and the related reports could be issued as per customer's requirements.

Applications of Our Custom Casting and Machining Parts:

1. Automobile Parts: Brake Disc, Connect Rod, Drive Axle, Drive Shaft, Control Arm, Gearbox Housing, Gearbox Cover, Clutch Cover, Clutch Housing, Wheels, Filter Housing, C.V. Joint Housing, Lock Hook.

2. Truck Parts: Rocker Arms, Transmission Gearbox, Drive Axles, Gear Housing, Gear Cover, Towing Eye, Connect Rod, Engine Block, Engine Cover, Joint Bolt, Power Takeoff, Crankshaft, Camshaft, Oil Pan.

3. Hydraulic Parts: Hydraulic Cylinder, Hydraulic Pump, Gerotor Housing, Vane, Bushing, Hydraulic Tank, Hydraulic Cylinder Head, Hydraulic Cylinder Triangle Bracket.

4. Agricultural Machinery and Tractor Parts: Gear Housing, Gear Cover, Connect Rod, Torque Rod, Engine Block, Engine Cover, Oil Pump Housing, Bracket, Hanger, Hook, Bracket.

5. Rail Trains and Freight Cars: Shock Absorber Housing, Shock Absorber Cover, Draft Gear Housing, Draft Gear Cover, Wedge and Cone, Wheels, Brake Systems, Handles, Guids.

6. Construction Machinery Parts: Gear, Bearing Seat, Gear Pump, Gearbox Housing, Gearbox Cover, Flange, Bushing, Boom Cylinder, Support Bracket, Hydraulic Tank, Bucket Teeth, Bucket.

7. Logistics Equipment Parts: Wheels, Caster, Bracket, Hydraulic Cylinder, Forklift Spare Parts, Lock Case,

8. Valve and Pump Parts: Valve Body (Housing), Butterfly Valve Disc, Ball Valve Housing, Flange, Connector, Camlock, Open Impeller, Close Impeller, Pump Housing (Body), Pump Cover.