Process Flow and Future Development of Lost Foam Casting
The Lost Foam Casting process typically begins with the design and fabrication of the foam pattern. Expandable polystyrene is shaped through pre-expansion, steam molding, thermal forming, and finishing to achieve accurate dimensions and a smooth surface. After inspection, multiple foam patterns are assembled into a casting cluster and coated with a high-performance refractory coating. The coating not only enhances shell strength but also helps maintain the outer geometry of the pattern during vaporization, ensuring better surface quality of the final casting. Once the coating dries completely, the cluster is placed inside a sand box, where dry sand is compacted around it through vibration to create a stable supporting mold. During pouring, the foam pattern decomposes under the high temperature, the gases escape through the coating’s permeability, and molten metal fills the cavity to form the part. After solidification, the casting can be removed, cleaned, and processed further as need...