Full-mold casting

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Full Mold casting (similar to lost foam casting) is a process in which a polystyrene foam pattern is made and coated with a Refractory material. This foam pattern is then put into a one piece sand mold. After the hot metal is poured into the mold the foam disintegrates and the metal fills in the empty void. The Polystyrene Foam pattern is made by expanding Polystyrene beads in preheated dies.


Contents

[edit] Advantages

  • This method of casting is good because no draft or flash are formed.
  • dimensions are highly accurate.
  • very simple and requires minimal finishing.
  • Cheap because roam is rather inexpensive
  • works good for casting of ferrous and nonferrous metals

[edit] Disadvantages

  • a new pattern is required for each casting.
  • It's expensive to produce the Die to expand the foam in.

[edit] Types of application

  • Cylinders heads
  • Engine Blocks
  • Manifolds
  • Anything with complex shapes.

[edit] Types of metal used

  • Aluminum
  • Iron
  • Steel
  • Nickel Alloys
  • Copper Alloys

[edit] Sources

  • Kalpakijian, Serope, and Steven R. Schmid. Manufacturing Engineering and Technology (Upper Saddle River: Pearson Prentice Hall, 2006), 297-299.


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